10-1 AXLES-PROPELLER SHAFTS - Tom 'Oljeep' …oljeep.com/gw/77_tsm/14 1977 10-Axles-Prop...
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Transcript of 10-1 AXLES-PROPELLER SHAFTS - Tom 'Oljeep' …oljeep.com/gw/77_tsm/14 1977 10-Axles-Prop...
AXLES-PROPELLER SHAFTS
PageFront Axle 10-3Propeller Shaft and Universal Joint 10-37RearAxle 10-11Specifications 10-38
Standard Differential.Testing and DiagnosisService ToolsTrac-Lok Differential.
Page10-17
10-110-4010-31
TESTING AND DIAGNOSIS
Audible VibrationAxle TestsAxle Noisy on CoastAxle Noisy on PullAxle Noisy on Pull and CoastBacklash
Page10-210-110-210-210-210-2
Chatter-Trac-Lok Differential.Drive Line VibrationGeneralOther Axle ConditionsTire Noise TestsWheel Bearing Tests
Page10-210-210-110-210-110-1
GENERALWhen diagnosingan axle noise condition, obtain a
completedescriptionof the noise anddriving conditionswhen the noise occurred.A preliminary road test withthe customerdemonstratingthe complaint condition isrecommended.
The actionof transmittingenginetorqueto thewheelswill producesome noise in all axles. Slight axle noisesconfinedto a shortspeedrangeor to a specificperiodareconsiderednormal.
Noises producedby the engine, transfercase,transmission, tires, wheel bearings, exhaustsystem,propeller shaft, or the action of wind on the body or grillemay be incorrectly diagnosedas producedby an axle.Thoroughly test the vehicle to isolate the problemcomponent.
Before roadtestingthevehicle, start the engine,shiftthe transmissioninto neutraland operatethe engineatvariousspeeds.If the noise is heardduring this test, thenoise is being generatedby the engine, exhaustsystem,clutch, transmission,transfercase,oi, by engine-drivenaccessoryequipment.
Before road testing, check and correct tire inflationpressuresandaxle lubricant levels.
TIRE NOISE TESTSBecausecertain types of tire treadwearor treadpat
terns may produceobjectionablenoises, drive the vehicle on various types of road surfacesand listen for achangein the noise. If the noise varieswith the type ofroadsurface,the tires may be the cause.
WHEEL BEARING TESTSWorn, loose,or damagedwheel bearingscan be con
fusedwith axle noises. Wheel bearingnoise is usuallymore noticeablewhen coastingat lower vehicle speeds.Applying the brakes gently will usually changewheelbearingnoise.Another testinvolves turning the vehiclealternatelyleft andright while movingstraightaheadatrelatively low speed.This manueverside-loadsthe bearings causingthe problem bearingto becomenoisy.
AXLE TESTSBefore testing the axle, drive the vehicle a distance
sufficient to warm the axles and axle lubricant. Duringthe test, operatethe transmissionand transfercase inevery gearcombination.
Axle noisesareusuallyrelatedto vehiclespeedratherthanenginerpm or transmissiongearrange.
Axle noises may be classified into two types: gearnoiseand bearingnoise.
Gear noise is often describedas a whine or high-pitchedresonatingsound.It is usuallymorepronouncedat certain vehicle speedsand within a narrow speedrangeundera drive acceleratingload, coastdecelerating load, or float constantspeedcondition.
Axle bearingnoise is usuallyconstantandthe pitch isrelatedto vehicle speed.
Sincethe pinion gearrotatesfasterthan the ringgear,the pinion bearingsproducea higher pitch soundthanthe differential bearings.The pinion bearingsare usually heardat lower vehiclespeeds20 to 30 mph.
10-1
10-2 AXLES-PROPELLER SHAFTS 1
Differential hearingsproducea lower pitch soundbecausethey are rotating at the samespeedas thewheels.Differential hearingnoisewill not vary whenthe vehicleis turnedalternately left and right or when the brakesare gently applied.
AXLE NOISY ON PULL AND COAST* Excessivering andpinion backlash.* Excessivepinion end play.* Worn pinion hearings.* Incorrectpinion depthadjustment.* Incorrect lubricant Trak-Lok differential.
AXLE NOISY ON PULL* Incorrect ring and pinion backlash or depth
ad,justment.* Damagedor worn pinion bearings.* Incorrect pinion bearingpreload.
AXLE NOISY ON COAST* Excessivering and pinion backlash.* Excessivepinion end play.* Worn or damagedpinion or differential bearings.
BACKLASHExcessivedriveline backlash may be the result of
backlashin the transmission,propeller shaft yoke orspline, universal joint, ring and pinion, differentialgears,or axle shaftsplines.
CHATTER-TRAC-LOK DIFFERENTIALChatter in the Trac-Lok rear differential is usually
caused by the use of improper lubricant. If improperlubricant is determinedto be the causeof chatter,drainand refill the axle with Jeep Trak-Lok lubricant orequivalentonly.
OTHER AXLE CONDITIONSA knocking noise heardat low speedor whencoasting
may he causedby loose fitting differential side gears.Whenthis condition is encountered,applyingthe brakeslightly will usuallyreducethe sound.
Differential gear noise is considerednormal whenspinninga wheelwith an on-the-vehiclewheelbalancer,or whenthe wheelsarespinningon an icy road surface.
When axle noisehasbeendeterminedto becausedbybearings,do not replacethe gearsunlessthey arewornor damaged.Similarily, if the axle gearsare causingnoise, do not replacethe bearingsunlessthey arewornor damaged.
DRIVELINE VIBRATIONDriveline vibration canbe causedby a varietyof con
ditions. The following procedurewill help to isolatethemostcommon causes.
1 Check tire condition. Look for differences intread wear, side-to-sideand front-to-rear. Be sure alltires are samesize, type, have matching treaddesign,and are at correct inflation pressures.Theseitems areespeciallyimportanton Quadra-Tracequippedvehicles.
2 Check and correct tire inflation pressures.Correctandequalinflation pressuresarevery importantonQuadra-Tracequippedvehicles.
3 Check for loose or damageddriveline componentsuniversal joints, engine/transmissionmounts,spring U-bolts, spring shackles,spring eye bushings,enginedriven accessoriesand belts.
4 Check front and rear axle pinion angles asfollows:
a Placevehicleon drive-ontype hoist or hoistthat will supportvehicle on all four tires.
b Check vehiclelevel using bubbleprotractor.Positionprotractor on straight portion of frame rail totake reading. If necessary,correctvehicle level by inserting shim betweentire andhoist ramp at low side ofvehicle.
c Check pinion angleusingbubbleprotractor.Placeprotractoron flangeof differential housingcoverto take reading. Although reading can be taken fromcover flange, most accuratereading is obtainedby removing housingcover,draining axle lubricant,andtaking reading directly from machined cover mountingsurfaceof housing.
d Refer to Pinion Angle Chart at end of thissection for specifications.
NOTE: All pinion anglesin the PinionAngleChart aregiven in degreesabovehorizontal.
e Adjust pinion angleas necessaryusingtaperedshims. Install shimsbetweenaxle springpadandspring.
AUDIBLE VIBRATIONOn someJeepmodelswith Quadra-Trac,an incorrect
rear axle pinion angle may generatean audible-typevibration. The vibration occursas a boomingor drone-like soundwhich is mostnoticeablein the 40 to 60 mphspeedrange.
If a vehicleexhibitsthis condition,the rearaxlepinionand engineanglesmustbe checked.If the anglesarenotwithin specified limits, shimsmust beinstalledbetweenthe rear axlespring padsandrearspringsto correcttheangles.Shimsareavailablein one,two, andthreedegreeincrementsfor this purpose.The procedurefor checkingandcorrectingthe pinion angleis as follows:
1 Placevehicleon level surface.2 Measureenginedownwardangleasfollows:
a Position protractor on left side of engineblock at transmissionmounting ear on engine block.Placeprotractorin fore andaft direction. Use mirror toview protractorif necessary.
1 AXLES-PROPELLER SHAFTS 10-3
h Recordenginedownwardangle,removeprotractor,and proceedto next step.
3 Measurepinion upwardangleasfollows:a Place protractor on left side of rear axle
housing, on flat machined surfaceof housing next toweldedplug. Be sure this surfaceis free of weld flash.
h Recorl pinion upward angle, remove protractor,and proceedto next step.
4 If pinion upwardangle is one degreeless thanenginedownwardangle,pinion angle is within specifiedlimits. Check for othercausesof vibration.
5 If pinion upward angle is greater than enginedownwardangleby more than onedegree,pinion anglemusthe adjustedasoutlined in next step.
degrees.This changesthe pinion downward angle to 4degreeswhich is the requiredone degreeless than theenginedownwardangle.
6 Adjust pinion angleas follows:a Raise rear of vehicle and place support
standsunderframerails.h Positionhydraulic jack underaxle housing
andraisejack just enoughto supportweight of axle.c Removerearwheels.d Loosenrearspring U-bolt nuts.e Install appropriatedegreetaperedshim be
tweenspring and axle spring pad. Install shim so thickest end is facing front of vehicleto adjustpinion angledownward.
f Tighten U-bolt nuts to 100 foot-poundsEXAMPLE: If the engine angle measures5 degreesdownwardand the pinion anglemeasures7 degreesupward, the pinion angle must he adjusted downward 3
torque.g Install rearwheels.h Removesupportstandsandlower vehicle.
FRONT AXLE
Axle HousingAxle ShaftAxle Shaft SealAxle Shaft Universal JointFront Axle Installation.Front Axle RemovalGeneralHigh Steering Effort
GENERALThe front axle usedon all Jeepmodelsis a drive-type
axle with hypoid gears and steering knuckles. Enginetorqueis transmittedto the wheelsthroughfull..floatingaxle shafts which have integral universal joints thatrevolvewithin andaresupportedby the steeringknuckles. All front axles use open end designsteeringknuckles. The knucklesare not enclosed.
CJ models use the model 30 front axle. Wagoneer,Cherokee,andTruck modelsusethe model 44 front axle.Refer to the Axle Application Chart at the end of thissection for details.
On all front axles, toe-in and casterare the only adjustablefront alignmentangles.Camberis built into theaxle and cannot he adjusted. Toe-in is adjusted bylengtheningor shorteningthe steeringtie rod. Casterisadjustedby installing taperedshimsbetweenthe springand axle pad. If caster is adjusted,the front axle pinionangle must also he adjusted.Refer to the Pinion AngleChart at the end of this section for details.
IDENTIFICATION
10-310-10
10-810-710-8
10-1010-5
10-38
The axle model code number is castsurfaceof the reinforcingrib at the lefthousingfig. 10-1.
The build dateand manufacturerspart numbersarestampedon the right-hand axle tube adjacent to thehousingcover.The build dateis decodedas follows: Thefirst numberis the month, thesecondnumberis thedayof the month, the third numberis the year, the letteristhe shift, and the last numberis the assemblyline. Ifthere are two build dates,the latter datewill indicatewhen the brakecomponentswere installed.
The gearratio tag, attachedto theleft side of theaxlehousingcover, indicatesthe Jeepmanufacturingreferencepart numberandthe tooth combinationof the ringandpinion gears.
Page10-4 Identification10-5 Spindle Bearing10-9 Steering Knuckle Installation10-6 Steering Knuckle Removal
10-10 Steering Knuckle Ball Stud10-10 Turning Angle Adjustment10-3 Pinion Seal and Yoke Replacement10-4 Specifications
Page
into the upperside of the axle
10-4 AXLES-PROPELLER SHAFTS
The front axle housingshould be inspectedperiodically for weld cracksor other damagethat could causeloss of axle lubricant, affect driving characteristics,orresult in front end misalignment.
If the vehicle is driven through water that is deepenough to cover the front hubs, the axle/wheel endsshouldbedisassembledand inspectedfor water damageandcontamination.All componentsshouldbe examined,cleaned, and lubricatedas necessarybefore assembly.Damaged parts should be replaced. During the inspection,pay particular attention to the axle bearingsandbrakecomponents.
HIGH STEERING EFFORTHigh steeringeffort or slow return of the steering
mechanismafter turns may be the result of excessivesteeringknuckle ball stud preload.If this conditionoccursandall other itemsaffectingsteeringeffort areOK,ball studpreloadshouldbe checkedas follows:
Ball Stud Preload Inspection1 Raisevehicle.2 Removefront wheels.3 Disconnectsteeringdamper, if equipped,from
tie rod andmove damperaside.4 Unlock steeringcolumn.5 Disconnectsteeringconnectingrod. On CJ mod
els, disconnectrod at right-sidesteeringknuckle.On allothermodels,disconnectrod from right-sideof steeringtie rod.
6 Removecotterpin from nut attachingtie rod toright-sidesteeringknuckle.
7 Rotatebothsteeringknucklesthrough completearc several times. Work from right-side of vehicle torotateknuckles.
8 Assemblesocketand 0-to-50 foot-poundtorquewrench and install wrench on steeringtie rod attachingnut.
V.
NOTE: The torque wrench mustbe positionedparalellwith the steering hnuc/cle arm to obtain an accurateieuding.
9 Rotate knuckles slowly and steadily through acomplete arc and measure torque required to rotateknuckles.
a If torquereadingis less than25 foot-pounds,turning effort is within specificationsandfault is not insteering knuckle. Check steering pump, gear, andcolumn.
b If torque reading is more than 25 foot-pounds,turningeffort is excessive.Proceedto nextstep.
10 Disconnectsteering tie rod from both steeringknuckles.
11 Install 1/2 x 1 inch bolt, flat washer,andnut intie rod hole in onesteeringknuckle.Tightenbolt andnutsecurely.
12 Assemblesocketand 0-to-25 foot-poundtorquewrench and install on bolt previously installed in steering knuckle.
13 Rotate steering knuckle slowly and steadilythrough completearc and measuretorque required toturn knuckle. Removetorquewrench,andnut andbolt.
14 Install bolt, flat washer,nut and torquewrenchon opposite steering knuckle and measuretorque requiredto turn knuckle.
a If torquereadingis lessthan 10 foot-pounds,steeringeffort is within specificationsandfault is not inknuckle ball studs. Checkfor tight or damagedtie rodendsand lubricateor replaceas necessaryand proceedto next step.
h If torque reading is more than 10 foot-pounds,turning effort is excessive.Proceedto Ball StudPreloadCorrectionprocedure.
15 Install steering tie rod and rod-end retainingnuts. Tighten nuts to 35 foot-poundstorque and installreplacementcotterpins.
16 Install steeringconnectingrod and rod-end retaining nut. Tighten nut to 60 foot-poundstorqueon CJmodels and 75 foot-poundstorque on all other modelsandinstall replacementcotterpin.
17 Connectsteeringdamperto tie rod, if equipped.18 Install front wheels.19 Lower vehicle.
Ball Stud Preload Correction1 Removefront axleshafts.2 Remove cotter pin and slotted nut from upper
ball studandloosen lower ball studjamnut.3 Unseat upper and lower ball stud by striking
upperball studwith leador rawhidehammer.4 Remove split ring seat from upper ball stud
usingTool J-25158.Discardseat.5 Remove lower ball stud jamnut and steering
knuckle.Discardjamnut.6 Clean upperball stud split ring seatthreadsand
clean lower ball stud taper in steeringknuckle. Clean
Fig 10-1 Axle Identification
AXLE HOUSING
VI AXLES-PROPELLER SHAFTS 10-5
threads and tapered surfacesof both ball studs andcleanthreadsin upperball studretainingnut.
7 Instal steering knuckle. Support knuckle byhand and install replacementlower ball stud jamnut.Finger tightenjamnutonly.
8 Install upperball studnut and tighten nut untillower ball stud is drawninto taperedhole in axle yoke.Do not install split ring seatat this time.
9 Tighten lower ball stud jamnut to 80 foot-poundstorque.
10 Removeupper ball stud nut and install replacement upperball studsplit ring seatusingTool J-25158.Tighten seatto 50 foot-poundstorque.
11 Install replacementnut on upper ball stud.Tighten nut to 100 foot-pounds torque and install replacementcotterpin.
NOTE: if the cotterpin holedoe.’ not ulign, tighten. thenut until the hole does align. Do not /ooSen the ‘nut toulgn the cotter pin, hole.
12 Install front axle shafts and steeringspindlesloosely and measureturning effort of each steeringknuckle asoutlinedin Ball Stud PreloadInspection.
a If less than 10 poundstorque is required torotateknuckles,proceedto next step.
b If more than 10 poundstorqueis requiredtorotateknuckles, replaceupperandlower ball studsandrepeatBali Stud PreloadCorrectionprocedure.
13 Install front axle shafts.14 Connect tie rod to steering knuckle arms.
Tighten tie rod end retaining nuts t,o 45 foot-poundstorque and install replacementcotterpins.
15 Connect steering connectingrod to tie rod.Tighten connectingrod-end retaining nut to 60 foot-poundstorque on CJ modelsand 75 foot-poundstorqueon all other models.Install replacementcotter pin.
16 Connectsteeringdamperto tie rod, if equipped.17 Install front wheels.18 Lower vehicle,
PINION SEAL AND FRONT YOKE REPLACEMENT1 Raisevehicle.2 Mark propeller shaft and yoke for assembly
alignmentreferenceanddisconnectpropellershaftfromyoke.
3 Removepinion nut andwasherusingsocketandhandleandTool J-8614-01fig. 10-2.
4 Removeyoke using Tool J-8614-01,02, 03 fig.10-3.
5 RemovepinionsealusingTool J-25180.6 Install replacementsealusingTool J-25104.7 Install yoke.8 Install pinion washerand nut. Tighten nut to
210 foot-poundstorque.9 Align reference marks on propeller shaft and
yoke and connect shaft to yoke. Tighten shaft-to-yokeattachingbolts or nuts to 16 foot-poundstorque.
10 Lower vehicle.
AXLE SHAFT
Removal-CJ Models1 Raisevehicle.2 On modelswith disc brakes,removecaliper.Re
fer to Brakesand Wheelssection.3 Removehubcap.4 Removedrive flangesnapring.5 On modelswith disc brakes,remove rotor hub
bolts andremovehubcover andgasket.6 On models with drum brakes, remove axle
flangebolts.7 RemoveaxleflangeusingTool J-25133.
Fig. 10-2 Removing Pinion Nut
Fig. 10-3 Removing Yoke
10-6 AXLES-PROPELLER SHAFTS VI
8 Straghtenlip of Iockwasherand remove outernut, lockwasher,inner adjustingnut, and bearinglock-washer.UseTool J-25103to removelocknut.
9 On modelswith disc brakes,removeouter bearing andremoverotor.
10 On models with drum brakes, remove outerbearingandremovebrakedrum. Do not damageoil sealduring removal. Retractbrakeshoesif drum is difficultto remove.
11 On modelswith drum brakes,removebrakesupport plate.
12 On modelswith disc brakes,removeadapterandsplashshield.
13 Removespindleandspindlebearing.14 Removeaxleshaftanduniversaljoint assembly.
Installation-CJ Models1 Cleanall partsthoroughly.2 Install axle shaft and universaljoint assembly.
Do not removeinner oil seal.3 Insertsplinedend of axle shaft into differential
side gear andpushshaft into place.4 Install spindleandinnerbearing.5 On modelswith drum brakes,install brake sup
port plate.6 On modelswith disc brakes,install splashshield
andadapter.7 Lubricate and install outer bearingin drum or
rotor.8 Install brakedrumor rotor.9 Install washer and adjusting nut. Tighten ad
justing nut to 50 foot-poundstorqueusingToo] J-25103,then loosennut 1/3 turn.
10 Install outer lockwasherandnut. Tighten nut to50 foot-poundstorque and bend lip of lockwasherovernut.
11 Install drive flangeand gasketandinstall flangeor rotor attachingbolts.
12 Install drive flangeretainingsnapring in grooveat outerend of axle shaft.
13 On modelswith disc brakes,install caliper. Refer to BrakesandWheelssection.
14 On modelswith disc brakes,install rotor hubcover andinstall bolts.
15 Install hubcap.l6 Install wheelandlowervehicle.
Removal-Wagonoer-Cherokee-Truck1 Raisevehicle.2 Removewheelanddustcover.3 Removeaxle shaft snapring, drive flange, pre
surespring,andspring retainer.4 Removeouter locknut, lockwasher,andadjust
ing nut usingTool J-6893.5 On models with disc brakes,remove bolts at
tachingcaliperto supportshieldandmove c1iperaside.
6 Remove rotor or brakedrum.Spring retainerandouterbearingwill be removedwith rotor or drum.
7 Remove nuts and bolts attaching spindle andsupport shield and removespindleandshield. If necessary, tap spindlewith rawhidemallet to removeit fromknucklefig. 10-4.
8 Removeaxleshaft.
Installation-Wagoneor-Cherokee-Truck1 Install axleshaft,spindle,andbearing.2 Install hub and drum or if equippedwith disc
brakes, install support shield, rotor and hub, andcaliper.
3 Install inner wheel bearingadjustingnut nuthas peg on one side. Tighten nut to 50 foot-poundstorque. Back off adjusting nut 1/4 turn maximumwhile rotating hub.
4 Install lockwasherso inner tab is aligned withspindle keyway and turn inner adjustingnut until pegengagesnearesthole in lockwasher.
5 Install outer locknut and tighten nut to 50 foot-poundstorqueminimum.
6 Install spring retainer, pressurespring, anddrive flange.
CAUTION: Install the spring retainerwith thecuppedside of the retainer facing toward the center of thevehicle.
7 Push drive flange inward to provide clearancefor axle shaftsnapring andinstall snapring.
8 Install wheelanddustcover.9 Lower vehicle.
AXLE SHAFT UNIVERSAL JOINT
Replacement1 Removeaxleshaft.2 Removesnaprings from bearingcupsfig. 10-5.3 Presson endof onebearingcup to pressopposite
bearingfrom yoke half.4 Turn yoke over and pressfirst bearingout by
pressingon exposedendof journalshaft.
NOTE: To avoid damaging the bearing, remove thebearing ‘using a brassdrift with aflat face that is about1/32-inchsmaller in diameterthan the hole in the yokearm.
5 Repeatabovestepto removeremainingbearingsand remove bearing cross-journalby sliding it to oneside andlifting out.
6 Wash all parts in cleaning solventand inspectpartsafter cleaning.Replaceany partthat showsextensive wear.
7 Packbearingcupsone-thirdfull of lubricantandinstall bearingrollers.
FIg. 10-4 Model 44 SteerIng Knuckle Components
AXLES-PROPELLER SHAFTS 10-7
COTTER PIN
J4O67
8 Insert bearings into axle shaft yoke half andseatthem firmly againstbearingshoulders.
9 Install bearingcross-journalwhile holdingbearings in a vertical position to preventhearingsfrom dropping out.
10 Pressbearingcup on journal from oppositesideuntil firmly seated.
11 Repeatsteps9 and10 on oppositejournal.12 Install snapringson bearingcups.
NOTE: if the universal joint binds when assembled,tap the yoke lightly to relieve any pressureon the bearings at eachendof the journal.
13 Install axleshaft.
STEERING KNUCKLE REMOVAL
NOTE: The open-enddesign.steeringknucklepivotsonball studs. Bail stud replacementrequires removalofthe axle shaftand steeringlcnuckle.
1 Removeaxle shaft.2 Disconnectsteeringtie-rod endat knucklearm.3 Removeanddiscardlower ball stud nut fig. 10-
SNAP RING
BEARING CUP
Fig. 10-5 Axle Shaft Universal Joint
4 Remove cotter pin from upper ball stud andloosen studnut until top edgeof nut is flush with top ofstud.
5 Unseatupper and lower hal studs using leadhammer.
6 Remove upper ball stud nut and steeringknuckle.
7 Removeupperball stud seatusing Nut Wrench
VI
RUBBER SEAL
UPPER BALL STUD
STUD NUT
LOCK
T
NEEDLEBEARING
LOWER BALLNUT
RUBBER SEAL
SPINDLE
LOWER BALL STUD
STEERINGKNUCKLE
BEAR II CUP
AXLE SHAFTYOKE HALF
CUP
AXLE SHAFTYOKE HALF
BEARING CUPBEARING
J42300
6. J-25158.
10-8 AXLES-PROPELLER SHAFTS VI
Fig. 10-6 Lower Ball Stud Nut Removal
STEERING KNUCKLE BALL STUD
Replacement1 Removelower ball studsnapring.2 Clamp knuckle assemblysecurely in vise with
upperball studpointing downward.3 Attach PlateJ-25211-1to spindlematingsurface
of knuckleassemblyfig. 10-7. PositionButton J-25211-3 on lower joint. Assembleand align Puller J-25215.Tighten puller screwto presslower stud out of knuckle.
4 DisassemblePuller J-25215.On CJ models, install Adapter J-25211-4 on puller screw with adaptershouldertowardheadof screw.Threadpuller nut abouthalfway onto screw. Place Button J-25211-3on upperjoint and install puller in knuckle fig. 10-8. Tightenscrew to removeupperball stud.
PULLER SCREW J-25215
5 Invert knuckle in vise. Position lower ball studin knuckle. Use Installer Cup J-25211-2, Adapter J25211-4,and PullerJ-25215screw and nut fig. 10-9 topressin the lower stud. Install ball studsnapring.
6 Position upper ball stud on knuckle. Use Installer Cup J-25211-2 and Puller J-25215 to press inupperball studfig. 10-10.
STEERING KNUCKLE INSTALLATION1 Install upperball studseatinto axle yoke.Top of
stud seatshould beflush with top of yoke.2 Install knuckle assemblyonto axle yoke. Install
lower stud nut. Hand-tighten nut only. Position andalign Nut Wrench J-25158, Buttom J-25211-3,Plate J25211-1, and Puller J-25212 fig. 10-11. Tighten pullerscrew until lower ball stud is held firmly in its seat.Tighten lower studnut to 75 foot-poundstorque85 foot-poundstorqueon CJ models.Removepuller andplate.
3 Use Nut Wrench J-25158to tighten upperballstud seatto 50 foot-poundstorquefig. 10-12.
4 Install upper stud nut and tighten to 100 foot-poundstorque. Install cotter pin. If cotter pin holes donot align, tighten nut until cotter pin can be installed.Do not loosen nut to align holes.
5 Connectsteeringtie rod. Tighten nutsto 50 foot-poundstorque.
,1
"
41070
Fig. 10-8 Upper Ball Stud Removal
PULLER J-25215
BUTTON J-25211-3
PLATE J.25211-1
Fig. 10-7 Lower Ball Stud Removal
AXIES-PROPELLEfi SHAFTS 10-9
Fig. 10-10 Upper Bail Stud Installation
NOTE: When thesteeriny Io cJJ’ e emovedor rel1ce1, c/i eck the turning u ny/c.
AXLE SHAFT SEALReplacement
1 Removesealfig. 10-13.2 Remove bronze thrust washer. If washe:r is
Fig. 10-12 Tightening Upper Bail Stud Seat
VI
I
PLATEJ-25211-1
J4 ‘I 076
Fig. 10-9 Lower Bail Stud Installation
Fig. 10-11 Steering Knuckle Installation
INSTALLER CAPJ.:2521 1-2
J41 077
worn, replaceit. Fig. 10-13 Axle Shaft Seal Replacement
10-10 AXLES-PROPELLER SHAFTS
3 Cleanareaof dirt andforeign matter.4 Install bronze washerwith chamferedside to
ward axle shaftseal.5 Install seal.Direct lip of sealtowardspindlefig.
10-13.6 Packwheel bearinggreasearoundthrust faceof
shaftandseal.Fill sealareaof spindlewith wheel bearing grease.
SPINDLE BEARING
Replacement
NOTE: Front axle spindlesare equippedwith a needlerollei hearing located at the ‘rear spindleflange ‘fi.q. 10-14.
1 Placespindle in vise. Usecautionandprotectallmachinedsurfaceson spindle.
2 Use an internal bearing puller and removeneedlehearing.
3 Cleanareaof dirt andforeignmatter.4 Usean internalbearinginstaller andinstall new
hearing.5 Packneedlehearingwith grease.
FRONT AXLE REMOVAL1 Raise and support front end. Position frame
standsat rearof front springs.2 Remove wheel covers, wheel locknuts, and
wheels.3 Index propeller shaft for assemblyreference,
andremovepropellershaft.4 Disconnectsteeringconnectingrod at ball and
socketconnectionon steeringknuckles.5 Disconnectshockabsorbersataxlehousing.
6 Disconnectbreathertubefrom axlehousing.7 Disconnectswaybar link bolts atspringclips.8 Remove brakedrums and support plates or
brakecalipers,huband rotor, andsupportshields.9 RemoveU-boltsandtie plates.
10 Support axle assembly on jack; raise jackslightly to relievespringtension.
11 Loosennutssecuringrearspringshacklesbut donot removebolts.
12 Removebolts securingfront springshacklesandrestspringson floor.
13 Pull jack and axle assemblyfrom underneathvehicle.
FRONT AXLE INSTALLATION1 Supportaxle assemblyon jack andslide assem
bly into position underneathvehicle.2 Raise springs and install bolts in front spring
shackles,but do not tighten.3 Lower axle assemblyon springsand rotateaxle
assemblyinto position.4 InstallU-bolts andtie plates.5 Tighten front andrearspringshacklebolts.6 On models with disc brakes, install support
shield, huh and rotor, and brake calipers. On modelswith drum brakes,install support platesand hubsanddrums.
7 Connectbreathertube.8 Connectshockabsorbers.9 Connect steering connecting rod at steering
knuckles.10 Install propellershaft. Align indexmarksmade
duringremoval.11 Install wheelsandwheel locknuts.12 Removesupportstandsandlower vehic]e.13 Tightenwheellocknutsandinstallwheel covers.14 Checkfront wheel alignment.15 Checkturningangle.
TURNING ANGLE ADJUSTMENTThe turning angle stopscrewsare locatedat the rear
of the steeringknucklejust abovethe axle centerline.Ifadjustmentis necessary,proceedas follows.
1 Loosenlocknut on turninganglestopscrew.2 Usinga turntableto measureangle,adjuststop-
screw to obtain proper turning angle seeSpecifications.
3 Tighten stopscrewlocknut.
NOTE: Turning adjusting screw inward increasesturning angle.Turningscrewoutward decreasesturningangle.
Turning Angle Specifications: On CJ models, setturning angle at 29 degrees. On Cherokee, Wagoneer,and Truck, setthe turning angle at 36 to 37 degrees.
VI
NEEDLEROLLERBEARING
Fig. 10-14 Spindle Bearing
J41079
AXLES-PROPELLER SHAFTS 10-11
REAR AXLE
PageAxle Housing 10-11Axle Shaft and Bearing Replacement 10-12General 10-11
GENERALCJ models usethe AMC/Jeepsemi-floatingrear axle
with an 8-7/8-inchdiameterring gear and taperedaxleshafts. Cherokee,Wagoneer,and Truck modelsuse theModel 44F semi-floating rear axle which has flangedaxle shafts. Truck models rated from 6800 to 8400GVWR use the Model 60 full-floating rearaxle. Refer tothe Axle Application Chart at the end of this section forfurther information.
IDENTIFICATION
CJ AxleThe axle ratio identification code letter is located on
the axle housingtube boss,adjacent to the dowel holefig. 10-15.
Letter Codes Chart
Letter RatioPin ion/DriveGear Teeth
Trac-Lok
Trac-Lok
Standard
Standard
N
M
A
L
3 54:1
4091
3 54:1
4 09:1
11/39
10/41
11/39
10/41
PageIdentification 10-11Pinion Seal and Yoke Replacement 10-15Rear Axle Hub Replacement-CJ Models 10-12
Cherokee-Wagoneer-Truck AxlesOn Model 44 rear axles, the model numberis castinto
the uppersurfaceof the left side reinforcing rib of thehousingfig. 10-1. On the Model 60 rearaxle, the modelnumberis castinto a bosson the lower right side of thehousing,adjacentto the housingcover.
The axle build dateandmanufacturer’spartnumbersare stampedon the right-hand tube, adjacentto thecover fig. 10-16. Thebuild dateof the axle is as follows.First numberis the month,secondnumberis the day ofthe month, third numberis the year,the aipha-lettteristhe shift and the last number is the assemblyline. Ifthereare two build dates,the latter will be the date inwhich the brakecomponentswere installed.
The gear ratio tag, attached to the left side of thehousingcover, indicates the Jeepmanufacturingreference part number, the tooth combinationof the drivegear andpinion, andthe gear ratio.
Axles equippedwith the Trac-Lok differential haveatag attachedwhich statesthat a speciallubricant mustbe usedfig. 10-16.Use only JeepTrac-LokLubricantorequivalent.
AXLE HOUSINGThe rear axle housingshould be checkedperiodically
for weld cracksandotherdamagethat may causelossoflubricantor affect driving characteristics.
If the vehicle is driven through water deepenoughtocover the hubs, the wheel endsshould be disassembledand inspectedfor water damageor contamination.
VI
60650
AXLE BUILD DATE
/GEAR RATIO TAG
/MANUFACTURER’SPART NUMBER
7SPECIAL TRAC-LOK LUBE TAG
Fig. 10-16 Axle identification
42299
Fig. 10-15 Axle Ratio Code Location AMC/Jeep Axle
10-12 AXLES-PROPELLER SHAFTS
Examine, clean, and replace damagedparts beforelubricating and assemblingthe wheel end components.Pay particular attention to the axle hearingsandbrakecomponents.
REAR AXLE HUB REPLACEMENT-CJ MODELS
Removal1 Removeaxle shaftdustcap.2 Removeaxle shaft nutandwasher.3 Raiseandsupportvehicle.4 Removewheelandtire.5 Remove screws attaching brake drum to rear
hub andremovedrum.6 Install Puller Tool J-25109-01on axle hub and
removehuhfig. 10-17.
CAUTION: Do not use a knockout or slide hammer-typepuller to removethe hub. This type ofpuller maylull lye axle hearings, axle shaft, or differential thrustblock.
InspectionInspect huh for loose or distorted wheel lug studs.
Inspectkeyway andtaperedcenterbore for wear,damaged serrations, or cracks. Replace hub if worn ordamaged.
Installation
NOTE: Proceduresfor installing an original hub andins tl lunga replacement hub differ.
Install an original hub as follows:1 Align keywayin hub with axle shaftkey.2 Slidehub ontoaxleshaftasfar as possible.3 Install axle shaftnut andwasher.
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4 Install drum, drum retaining screws,and roadwheel.
5 Lower vehicle onto wheels. Tighten axle shaftnut to 250 foot-poundstorque. If cotterkey hole is notaligned,tighten nut to the next castellationandinstallcotterkey. Do not loosen nut to align cotterkey hole.
NOTE: When a replacementaxle shaft is installed, areplacementhub must also be installed. However, areplacementhub may be ‘installed on an original axleshaft if the serrations on the shaft are not worn orIan,aged.
Install a replacementhub as follows:1 Align keyway in hubwith axleshaftkey.2 Install two well-lubricated thrust washersand
axle shaftnut.3 Install drum, drum retaining screws,and road
wheel.4 Lower vehicle onto wheels. Tighten axle shaft
nut until distancefrom hub outer face to axle shaftouter end is 1.30 inchesfig. 10-18.
NOTE: Pressing hub onto axle shaft to specifieddimension is necessaryto form hub serrationsproperly.
5 Removeaxle shaftnut andonethrustwasher.6 Install axle shaft nut and tighten to 250 foot-
poundstorque. If cotter pin hole is not aligned,tightennut to next castellationand install cotter pin. Do notloosennut to align cotterpin hole.
AXLE SHAFT AND BEARING REPLACEMENT
Removal-Tapered Shaft1 Remove rear wheel, drum, and hub as outlined
in RearAxle Hub Replacement.2 Disconnectparkingbrakecableat equalizer.3 Disconnectbrake line at wheel cylinderand re
move brake supportplate assembly,oil seal, andshimsfrom axle shaft.
Fig. 10-17 Removing Rear Axle Hub-CJ Models
Fig. 10-18 Replacement Hub Installation Measurement In inches
AXLES-PROPELLER SHAFTS 10-13
NOTE: if both axleshafts arc rmued, keep the shimsseparated.Axle shaft cud phiij ‘s iijusted on the leftside only.
4 Use Axle Shaft Bearing Puller Tool J-2498 toremoveaxle shaft andhearingfig. 10-19.
5 Removeanddiscardaxleshaft inner oil seal.
NOTE: Bearing coneis press-fit on axleshaftandmustbe removed using an arbor press fig 10-20.
Installation-Tapered ShaftTaperedshaft axle bearingshave no provision for
lubrication after assemblyand must be packed with agood quality wheel bearingluricant before installation.
1 Pressaxle shaft hearings onto axle shafts.Small diameterof conemust facetoward outer taperedendof shaft.
NOTE: 7oat inner axle shaft seal with a light lubricatng oil.
2 Coat outer surfaceof seal metal retainerwithnonhardeningsealer.
3 Install inner oil seal using Axle Shaft Seal Installer J-21788fig. 10-21.
4 Install axle shafts. Align splinedend with differential gears.
5 Install outer bearingcup.6 Inspect brake support plate for elongatedbolt
holes.Replacesupportplate if necessary.
NOTE: During assembly,apply a silicone sealermaterial to the axle tube .tiange and bra/ce support plate
A4142 1 ui ountiny area to prevententry ofdust and water.
7 Install original axle endplay shims, oil seal assembly, and brake support plate. Tighten attachingbolts to 35 foot-poundstorque.
NOTE: The oil seal and retainer are located on the
End Play AdjustmentAxle shaft end play is adjustedat the left side axle
shaftonly.1 Strikeend of eachaxle shaftwith lead hammer
to seatbearingcupsagainstsupportplate.2 Attach Axle Shaft End Play Tool J-2092 to end
of left side axle shaft. Mount dial indicator on support
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TOOLJ-2498
Fig. 10-19 Removing Axle Shaft
outscdeof bra/ce supportplate.
/TOOLJ-21 788
41423
Fig. 10-21 Installing Inner Seal
Fig. 10-20 Removing Axle Shaft Bearing
10-14 AXLES-PROPELLER SHAFTS
plate or tool, and check end play while pushing andpulling on axle shaftfig. 10-22.
3 Endplay shouldhe0.004 to 0.008 inch, 0.006 inchis desired.
4 Add shimsto increaseendplay, removeshimstodecreaseend play.
5 Install huh and drum as outlined in RearAxleHuh-Installation.
6 After axle shaft end play is checkedand corrected,adjustbrakesasoutlined in Brake Section.
Removal-Flanged Shaft1 Raiseandsupportvehicleandremovewheels.2. Removebrake drum locknutsspring-type and
removedrum.3 Remove axle shaft flange cup plug by piercing
centerwith sharptool andprying out.4 Remove nuts attaching support plate and re
tainer to axle tube flange usingaccesshole in axle shaftflange.
5 AssembleAdapter Tool J-21579and SlideHammer J-2619, install tools on axle shaft flange, and remove axle shaft fig. 10-23.
NOTE: Be sure the original bearing cup is removediii f/ic urIc housing.
tube.6 Remove axle shaft oil seal from axle housing
7 Wipe seal bore in axle housingtube clean andinstall oil seal usingDriver J-25135.
CAUTION: Under no circumstancesshould the axle.shatt iefannng rings or bearings be removedusing atorch. Heat will transfer info the axle sha.ft bearingiou rnal and weakenit.
TOOL TOOLJ-21579 J-2619-O1
70543
Fig. 10-23 Removing Flanged Axle Shaft
Bearing Replacement
1 Mount axleshaft in vise.2 Drill 1/4 inch diameter hole in retainer ring.
Hole depth should be approximately3/4 of ring thickness.Do not allow drill to contactaxle shaft.
3 Positionchiseloverdrilled hole in retainerbearing. Cut deepgroove in retainingring usingchisel. Thiswill enlargering, or split it, allowing ring to be removedfrom axle shaftfig. 10-24.
4 Cut through oil seal usinghacksawandremoveseal and retainer plate. Do not damageseal contactsurface.
5 Inspectaxle shaftoil sealjournal for scratches.Removescratchesusingcrocuscloth.
6 Install retainerplateon axle shaft.7 Pack wheel hearinggreasein oil seal cavity and
betweenseallips and install sealon axle shaftseal seat.Outerfaceof sealmust faceaxle flange.
J42302
VI
/
Fig. 10-22 Checking Axle Shaft End Play
Fig. 10-24 Notching Bearing Retainer Ring
AXLES-PROPELLER SHAFTS 10-15VI
8 Packreplacementaxle hearingwith wheel bear-ing grease.
9 Install hearing on axle shafi:. Be sure cup ribring is facingaxle flange.
10 Install hearingretainerring en axle shaft.11 Using Tool J-23674and arbor press, pressaxle
shafthearingandretainerring on axle shaftsimultaneously. Be sure hearing and retainer ring are properlyseatedagainstaxle shaftshoulder,
Installation-Flanged Shaft1 Instafl axle shaft through supportplate.Do not
damageaxle housingtube inner oil seal.2 Apply coatingof wheelhearinggreaseto outside
diameterof hearing cup before installing in bearingbore.
3 Tap end of flanged shaft lightly with rawhidemallet to position axle shaft hearing in bearingbore ofhousing.
4 Attach axle shaft retainer and brake supportplate to axle tube flange. Install attaching nuts andlockwashers.
5 Install cup plug in axle shaft flangehole,6 Install brake drum, spring-type locknuts, and
rearwheels.7 Removesupportsandlower vehicle.
Removal-Full-Floating Shaft Model 60
NOTE: It is not necessaryto raise f/ic rear wheelsinorder to ic more the rca r axle sh1 ff5 Oil Model 60 .full-f7oatiny reai axles.
1 Removeaxleflange nuts, lockwashers,andsplitwashersretainingaxle shaftflange fig. 10-26.
2 Removeaxleshaft from housing.
Installation-Full-Floating Shaft Model 601 Be sureaxle flange matingareaon hub andaxle
arecleanandfree of old gasketmaterial.2 Install replacementflangegasketon hub studs.3 Insertaxleshaftinto housing.
NOTE: It will be necessaryto rotate the axle shaft tosiunultaiicouislij Iligli f/ic shaftsplineswith f/ic differentill gear splinesand theflange attachingholes with theliutb st/U/s.
4 Install split washers,Iockwashers, and flangebolts. rfighten bolts.
PINION SEAL AND YOKE REPLACEMENTSemi-Floating Axle with Tapered Shaft
1 Raise and support vehicle. Removerear wheelsandbrake drums.
2 Disconnectpropeller shaft from rear yoke. Index shaft to yoke for assemblyreference.
3 Rotate drive pinion several revolutions usingSocket Tool J-22575 and inch-pound torque wrench tomeasuretorquerequiredto turn drive pinion.
NOTE: The torque required to turn the drive pinioninust be recorded.toi rofcrcnccat time o.f asscrnbly.
4 Removepinion nut usingTool J-8614-01fig. 10-2. Discard pinion nut.
5 Mark yoke andpinion for alignmentreferenceattime of assemhly.
6 Remove yoke using Tools J-8614-01,02,03fig.10-3.
7 Inspect seal surfaceof yoke. If surfaceis damagedor grooved,replaceyoke.
8 Remove pinion seal using Tool J-9233 fig. 10-26.
9 Before installing replacementseal, coatseal lipwith rear axle lubricant.
10 Install sealusingTool J-22661fig. 10-27.11 Install yoke on pinion. Note alignment marks.
Install replacementpinion nut. Tighten nut usingToolsJ-8641-01andJ-22575to removepinion bearingendplayonly. Do not overtighten.
12 Check torquerequired to turn drive pinion. Pinion must he turned severalrevolutions to obtain accurate torque reading. Refer to torque readingrecordedduring disassemblyand add 5 inch-poundsfor properamountof torque.
13 If preload torque is less than desiredamountdisassembly torque reading plus 5 inch-pounds,tighten pinion nut slightly andcheck torque.
14 Repeatthese steps until desiredtorque is attained.Do not loosenand retighten nut.
CAUTION: Io iuof o i’crtigh ten the pinion uiut. if f/icdesiredtorqnc is cxcccdcI, a uicin coiia]sibie pillion spa-cci s/cccc in nsf be ins failed and the pinion gear preloadreset.Rt’r to Differential Over/ian!.
Axle Models 30, 44, and AMC/ieep areall semi-float
ing type axles. Only the Model 60 is a full-floating type 11
TOOL J-23674
Fig. 10-25 Removing Axle Shaft Bearing
10-16 AXLES-PROPELLER SHAFTS
15 Install propeller shaft. Align index marksmadeat disassembly
16 Install rearbrakedrumsandwheels.
TOOLJ-22661
Semi-Floating and Full-Floating Axles with Flange Shaft1 Raiseandsupportvehicle.2 Index propeller shaftto front yoke for assembly
referenceanddisconnectshaftat yoke.3 Remove pinion nut and washer using Tool J
8614-01.4 Remove yoke using Tools J-8614-01,02,03fig.
10-3.5 On semi-floatingaxle, removepinion seal using
Tool J-25180.On full-floating axle, useTool J-25144.
6 Install replacementoil seal usingInstaller ToolJ-25104.
7 Install yoke on pinion.8 Install pinion washer and nut. Tighten nut to
210 foot-poundstorqueon Model 44 and260 foot-poundstorqueon Model 60.
9 Align index marks on propeller shaft and yokeand install shaft. Tighten attachingbolts or nuts to 16foot-poundstorque.
10 Removesupportsandlowervehicle.
REAR AXLE REMOVAL1 Raisevehicle and positionsupportstandsunder
framerails just forward of rear springs.2 Removewheels.3 Index propellershaftat yoke for assemblyrefer
enceanddisconnectpropellershaft.4 Disconnectshockabsorbersfrom axletubes.5 Disconnectbrake hydraulichoseat rear axletee
fitting. Tapeendsof hoseandfitting to keepout dirt.6 Disconnectparkingbrakecableto equalizer.7 Supportaxle on hydraulicjack.8 Remove U-bolts. On vehicle with spring-
mountedaboveaxle, disconnectshacklebolts and movespring away from axle.
9 Slide axlefrom undervehicle.
REAR AXLE INSTALLATION
NOTE: All service replacementaxle assembliesares/upped.from the factory without lubricant in the differential. Lubricant must be added to the thfferential be.thre the axle is installed. Use Gear Lubricant GradeSAE8Oftn standard axles. UseJeepTrac-LokLubricantor equivolen t in Trox-Lok axles.
When addingdifferential lubricant, suspendthe axlewith the axleshaftsin ahorizontalpositionandtheyokeend of the pinion housingfacingdownward.Then, turnthe pinion shaftseveraltimes to be sure that lubricantreachesthe pinion bearings.
1 Support axle assemblyon hydraulic jack andpositionaxle undervehicle.
41428 2 Align springs with axle spring pads,and installU-bolts and nuts. On vehicles with spring-mountedaboveaxle, position spring on shackleand install bolts.Do not tighten bolts completely.
3 Attach brake line hose at tee fitting on top ofhousing.
4 Connectparkingbrakecables.5 Connectshockabsorbersto axle tubes.6 Install propeller shaft. Align marks madedur
ing removal.7 Bleedbrakesandadjust.8 Install wheels, remove supports, and lower
vehicle.9 Check lubricant level and add lubricant as
V.
/TOOLJ-9233
Fig. 10-26 Removing Pinion Seal
/
Fig. 10-27 Installing Pinion Seal
required.
STANDARD DIFFERENTIAL
AXLES-PROPELLER SHAFTS 10-17
PageDifferential Operation . 10-17General 10-17
GENERALCJ modelsusethe Model 30 front axle and the AMC/
Jeeprear axle, which has an 8-7/8-inch ring gear andtaperedaxle shafts.
Cherokee,Wagoneer,andTruck modelsusethe Model44F front axle and the Model 44 rear axle with flangedaxle shafts.Truck models ratedat 6800 GVWR and upusethe Model 60 full-floating rear axLe.
Axle Models 30, 44, and AMC/Jeepare all semi-floating type axles. Only the Model 60 is a full-floating typeunit.
DIFFERENTIAL OPERATIONThe differential gear systemdivides the torque be
tweenthe axle shaftsand allows them to rotate at differentspeedswhenturning corners.
Eachdifferential side gear is splinedto an axle shaft.The pinion gearsare mounted on a pinion mate shaftand are free to rotateon the shaft. The pinion gear isfitted in a bore in the differential caseand is positionedat a right angle to the axle shafts
In operation,powerflow is as follows: the piniongearrotatesthe ring gear.The ring gear,being bolted to thedifferential case,rotatesthe case The differential pinion gears,which are mounted on the pinion mateshaftwhich is fitted in the case,rotate the side gears.Theside gears,which are splined to the axle shafts, rotatethe shafts.
During straight-aheaddriving, the differential piniongears do not rotate on the pinion mate shaft becauseinput torqueon thegearsis equally divided betweenthetwo sidegears.As a result,the pinion gearsrevolvewiththe pinion shaft, but do not rotatearoundit fig. 10-28.
Whenturning corners,the outsidewheelhasto travelfarther than the insidewheel. This difference in travelmust be compensatedfor in order to preventthe wheelsfrom scuffing and sliding through the’ turn. To accomplish this, the differential becomeseffectivearid allowsthe axle shaftsto rotateat unequalspeedsfig. 10-29.
DIFFERENTIAL OVERHAUL-AMC/JEEP AXLE
Disassembly
NOTE: It is not necessaryto remoi’c the reav’ axleassemblyto overhaulthe differential.Refertofigure 10-30for parts nomenclatureduring overhaul.
PageOverhaul-AMC/Jeep Axle 10-17Overhaul-Axle Model 30-44-60 10-25
IN STRAIGHT AHEAD DRIVING,EACH WHEEL ROTATES AT 100%OF CASE SPEED
*
A501 13
Fig. 10-28 Differential Operation-Straight-Ahead Driving
/OUTER WHEEL
Fig. 10-29 Differential Operation-On Turns
A501 14
1 Removeaxleshaftdustcapsandretainingnuts.2 Raiseandsupportvehicle.3 Removeaxle housingcover anddrainlubricant.4 Removewheels, brakedrums, hubs,axle shafts,
and seals.Keep left and right side axle parts separated.5 Mark bearingcapswith centerpunch for assem
bly refe:rence.
VI
GEAR
PINION GEARS ROTATEWITH CASE
AXLEç.//
100% DIFFERENTIAL INNER WHEELCASE SPEED 90% CASE SPEED
10-18 AXLES-PROPELLER SHAFTS
SHIM
Fig. 10-30 AMC-Jeep Rear Axle CJ Models
6 Loosen hearing cap bolts until only severalthreadsareengaged,then pull bearingcapsaway frombearings.This will preventdifferential from falling outandsustainingdamagewhenpried from axle housing.
7 Pry differential loose in axlehousing.8 Removebearingcapsandremovedifferential.9 Tie differential bearingshimsto their respective
bearingcapsandcupsto preventmisplacement.
Differential Bearing Removal
Use Puller J-2497-01 to removedifferential bearingconesfrom differential casefig. 10-31.Whenusingthistool, be sure it pulls on bearingcone in such a mannerthat rollers are free. If puller bears on bearingrollercage,it will damagecage.
Ring Gear Removal
1 Removering gear-to-differentialcasebolts.2 Using brassdrift, tap ring gear from case.Do
not nick ring gearfaceof differential caseor drop gear.
CASE
DIFFERENTIAL
VI
FRONT PINION BEARING
PINIONNUT
OIL SEAL
YOKE
BEARINGCUP
THRUSTWASHERS
MATESHAFT
COLLAPSIBLESPACER
GASKET
COVER
BEARINGCAP
AXLESHAFT
SHIM
OIL SEAL
DIFFERENTIALBEARING BEARING
SEAL
____________
RETAINER
60653
TOOL
41430
CAUTION: Do not chiselor wedgegearfrom case. Fig. 10-31 Removing Differential Bearing
AXLES-PROPELLER SHAFTS 10-19
Pinion Mate Shaft Removal1 Using3/16-inch diameterdrift at least3 inches
long drive out lockpin that holds pinion mate shaft inplacefig. 10-32.
2 Remove pinion mate shaft and remove thrustblock fig. 10-33.
3 Roll pinion gearsaroundcan be removedfrom case,thenthrustwashers.
L
on .idegearsuntil theyreml e side gearsand
41431
Fig. 10-32 Removing Pinion Mate Shaft Lockpin
Fig. 10-33 Removing Pinion Mate Shaft and Thrust Block
Pinon Gear Removal1 Removepinion nut usingTool J-8614-01fig. 10-
10-3.2 Remove yoke using Tools J-8614-01,02,03fig.
3 Install housingcover after removingnut. Securecover with two bolts to preventpinion gear from fallingout when it is driven out of housing.
4 Removepinion seal, tap end of pinion gear withfiber hammerto free front bearingcone from piniongear,and removehearing.
NOTE: A collapsiblespacer is used to control pinionbearing preload. Discard this spacer, it is not reusable.
5 Remove housing cover, pinion gear, and rearbearingfrom housing.
Pinion Rear Bearing Cup Removal
1 Removerearbearingcup usingDriver HandleJ8592 andCup RemoverJ-21786.
NOTE: Pinion depth adjustmentshimsare located behind rear bearing cup. Tag shims for assemblyreftrencc.
2 Removefront bearingcup usingDriver HandleJ-8592andCup RemoverJ-21787.
CAUTION: Keepcups square in bore to preventdam1gng cup bores.
Cleaning and InspectionClean all parts in solvent. Allow bearingsto air dry.
Dry other partswith compressedair.Inspect differential bearingcones, cups, and rollers
for pitting, galling, flat spots,or cracks.Inspectdifferential casefor elongatedor enlargedpin
ion mate shaft hole. The machinedthrust washersurface areasand counterboresmustbe smoothandfree ofnicks,gouges,cracks,or burrs. Inspectdifferential casefor cracksor othervisible damagewhich would necessitate replacement.
Inspectpinion mate shaft for excessivewear in contact areaof differential pinions.Shaft shouldbe smoothandroundwith no scoringor metal pickup.
Inspect side gears and pinions; they should havesmooth teeth with a uniform contactpattern withoutexcessivewear or broken surfaces.The side gear andpinion thrust washersshould be smooth and free fromany scoringor metal pickup.
Inspectpinion mateshaft lockpin for damageor loosenessin case.Replacepin or caseas necessary.
Inspectring gearandpinion for worn or chippedteethor damagedattaching bolt threads. If replacementisnecessary,replace both the ring gear and pinion asmatchedset only.
Inspect pinion bearing cones, cups, and rollers forpitting, galling, excessivewear,or othervisible damage.If inspection reveals that either are unfit for furtherservice,replaceboth cup andcone.
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I
2
10-20 AXLES-PROPELLER SHAFTS
Inspectaxle housingfor cracksor other visible damagewhich might necessitatereplacement.Raisedmetalon shoulderof bearingcup bores incurred in removingpinion cupsshouldbe flattenedusinga blunt punch.
Inspectpinion gearfor damagedbearingjournalsandmountingshim surfacesor excessivelyworn splines.Ifreplacementis necessary,replaceboth the pinion gearandring gear availablein matchedsetsonly.
Inspect pinion yoke for cracks, worn splines,pitted,rough or corrodedoil seal contactingsurface.Repair orreplacepinion yoke as necessary.
Inspect pinion bearing shim pack for broken, damaged, or distorted shims. Replace shims if necessaryduring settingof pinion bearingpreload.
Assembly1 Install rear bearingon pinion gear with large
diameter of roller case toward gear. Press bearingagainstrearfaceof gear.
2 Clean axle housing bearing bores to correctlycheckpinion geardepth.
NOTE: Wheninstalling a newgear set, usethe originaldepthshim asstarting point.
3 Install shim in rearbearingboreof housingandinstall rear bearingcup with Driver HandleJ-8592andBearingCup InstallerJ-8608fig. 10-34.
NOTE: Install shimwith chamferedsidefacingbottomof bearing cup borein housing.if shimis notchamfered,be sure shimis centeredwhen installed to preventmis-aligning bearing cup when it is installed.
VI
4 Install front bearingcup usingDriver HandleJ8592 andBearingCup InstallerJ-8611-01.
5 Insertpinion gear throughrearbearingcup. Install front bearing,rearuniversaljoint yoke, and original pinion gear nut. Tighten nut only enough toremove bearing end play.
NOTE: A new nut and collapsiblespacershouldnot beinstalled at this time becausethe pinion will gear beremovedafter depthmeasurement.
Pinion Gear Depth
Pinion gear depthrefers to the distancemeasuredininches from the end face of the pinion gear to thecenterlineof the axle shaftsfig. 10-35.This dimensionis controlled by shims which are installedbetweenthepinion gear inner bearingcup and the axle housingfig.10-30.
Ring andpinion gear setsare factory testedto detectmachiningvariances.The test is startedat a standardsettingwhich is thenvariedto obtain the mostdesirabletooth contactpattern and quiet operation.When thissettingis determined,the ring gearand pinion gear areetchedwith identifying numbersfig. 10-36.
The ring gear receivesone number.The pinion gearreceivestwo numberswhich areseparatedby a plus+or minus - sign.
The secondnumberon the piniongearindicatespinionposition in relation to the centerlineof the axle shaftswhere tooth contact was best and gear operationwasquietest.This numberis the pinion depthvariance.Thenumberon the ring gear andfirst numberon the piniongearidentify thegearsasamatchedset.Do notattempttouse a ring and pinion gear set thathavedifferent numbers.This is not a matchedset.
The secondnumberon the pinion gear indicatestheamount, in thousandthsof an inch, that the gear setvariedfrom the standardsetting. When the pinion gearis markedplus, the distancefrom the pinion end facetothe axle shaftcenterlinemust be more than the standardsetting. Whenthe pinion gearis markedminus,thedistancefrom the pinion end faceto the axle shaft centerline must be less than the standardsetting. Thestandardsetting for the AMC/Jeepaxle is 2.547 inchesfig. 10-35.
NOTE: Servicereplacementgear sets marked + or -0.009 or more shouldbereturned to the PartsDistribution Center. Do not attempt to install thesegear sets.The numberon the pinion gear mustmatch thefirst ofthe two numbersofthe ring pinion. If thenumberon thepinion gear differs from the first numberon the ringpinion, the gear setis not matched.
Fig. 10-34 installing Pinion Rear Bearing Cup
Fig. 10-35 Standard Setting Dimension and Pinion Depth Shim Location
Fig. 10-36 Ring and Pinion Gear Markings
Pinion Gear Depth MeasurementObservethe pinion depth variancemarkedon thepin
ion gear. If the numberis precededby a plus + sign,add that amount in thousandsto the standardsettingfor the axle model being overhauled.If the numberis
AXLES-PROPELLER SHAFTS 10-21
2.547
_____
INCH ES
_____
AMC/JEEP
AXLE
STANDARDSETTINGDIMENSION
AXLE SHAFTCENTERLINE
A4 1439
precededby a minus - sign, subtractthat amount inthousandthsfrom the standardsetting. The result ofthis addition or subtractionis the desiredpinion depth.Recordthis figurefor future reference.
1 Assemble Arbor Tool J-5223-4 and Discs J55223-23and install in differential bearingcup boresinaxle housing.Be surediscsareseatedin bearingbores.
2 Install bearing caps in axle housing and overdiscsfig. 10-37.Tighten bearingcapbolts securely,butnot to specifiedtorque.
3 Position Gauge Block J-5223-20on end face ofpinion gearwith anvil endof gaugeblock seatedon gearandplungerunderneathArbor Tool J-5223-4fig. 10-37.
4 Mount Clamp and Bolt AssemblyJ-5223-24onaxle housingfig. 10-37. Use housingcover bolt to attachclampto housing.
5 Extendclamp bolt until it pressesagainstgaugeblock with enough force to preventgaugeblock frommoving.
6 Loosen thumbscrewin gauge block to releaseplunger in gaugeblock. When plunger contactsarbortool, tighten thumbscrewto lock plungerin position.Donot disturb plungerposition.
7 Remove clamp and bolt assembly from axlehousing.
8 Removegaugeblock andmeasuredistancefromend of anvil to end of plunger using a 2- to 3-inch micrometer fig. 10-38. This dimension representsthemeasuredpinion depth. Recordthis dimensionfor assemblyreference.
V.
COLLAPSIBLESPACER
DEPTHSHIM
10-22 AXLES-PROPELLER SHAFTS
9 Removebearingcapsand removearbor tool anddiscs from axle housing.
10 Removepinion gear,rearbearingcup,anddepthshim from axlehousing.
11 Measure thickness of depth shim removed instep 10. Add this dimensionto measuredpinion depthobtainedin step8. From this total, subtractthe desiredpinion depth. The result representsthe correct shimthicknessrequired.
NOTE: Desired pzmon depth is the standard settingplus or minusthe pinion depthvariance.
The following examplesillustrate the procedurefordeterminingcorrectshim thickness.
Example I-Pinion DepthVarianceis Plus +
VI
Add pinion depthvariancemarkedon pinion geartostandardsetting. Resultis desiredpinion depth.
Step2-Determinetotal measuredpinion depth
2.547+0.007
2.554
Add measuredpinion depth to measuredshim thickness.Resultis total measuredpinion depth.
Step3-Determinecorrectshim thickness
2.550+0.101
2.651
Subtract desiredpinion depth from total measuredpinion depth.Resultis correctshim thickness.
Example Il-Pinion DepthVarianceis Minus -
Step1-Obtain desiredpiniondepth
2.651-2.554
0.097
Subtract pinion depth variance marked on piniongear from standardsetting. Result is desiredpiniondepth.
Step2-Determinetotal measuredpinion depth
2.547-0.003
2.544
Add measuredpinion depth to measuredshim thickness.Resultequalstotal measuredpinion depth.
Step3-Determinecorrectshim thickness
2.553+0.096
2.649
Subtract desiredpinion depth from total measuredpinion depth.Resultis correctshim thickness.
2.649-2.544
0.105
12 Install correct thicknessshims in axle housingbearingcup boreandinstall rearbearingcup andpiniongear.
Pinion Gear Bearing Preload Adjustment
1 Install collapsible spacerand front bearingonpinion gear.Install pinion oil sealusingInstallerTool J22661 fig. 10-27.
Fig. 10-37 Installing Pinion Depth Gauge Tools
GAUGE BLOCKJ-5223-20
Fig. 10-38 Measuring Gauge Block
Step1-Determinedesiredpinion depth
AXLES-PROPELLER SHAFTS 10-23
CAUTION: Collapsible spacercontrolspreload on pinion gear bearings.Do not reuse011 spacer. Usenewpartonly.
2 Install pinion yoke and new pinion nut. Tightenpinion nut finger-tight only.
3 Install J-8614-01on yoke and tightenpinion nutonly enoughto removeend play and seatbearings.Rotatepinion while tighteningnut to seatbearingsevenly.UseTool J-22575to tighten pinion nut.
4 RemoveTools J-8614-01 and J-22575 and checktorque required to turn pinion gear. Use Tool J-22575and inch-poundtorque wrench to check.Correctpinionbearingpreloadtorque is 17 to 25 inch-poundstorque.Continue tightening pinion nut until required preloadtorqueis obtained.
CAUTION: Do not exceedthe spec?.twdp reload torque.Do not loosen the nut to reducepreToad torque if thespecfiedtorque is exceeded.
5 If pinion bearing preload torque is exceeded,replace pinion nut and collapsible spacer and adjustpreloadto correcttorque.
Differential Case Assembly1 Install differential bearingson case using In
staller Tool J-21784 and Driver HandleJ-8592 fig. 10-39.
2 Install thrustwasherson differential side gearsand install gearsin differntial case.
3 Install differential pinion gearsin case and install thrustwashersbehindpinion gears.Align boresinpinion gears.
TOOLJ-8592
4 Rotatedifferential side andpinion gearsin caseuntil pinion mateshaftboresin piniongearsarealignedwith shaftboresin case.
5 Install thrust block in case.Insertblock throughbore in side gear.Align bore in block with pinion mateshaftboresin gearsandcase.
6 Install pinion mate shaft. Align lockpin bore inshaftwith bore in caseandinstall lockpin.
Differential Bearing Adjustment
1 Placehearingcup overeachdifferential bearingandinstall differential caseassemblyin axle housing.
2 Install shim on each side betweenbearingcupand housing.Use0.080-inchshimsasstarting point fig.10-40.
3 Install hearing caps and tighten bolts fingertight. Mount dial indicatoras shown in figure 10-41.
4 Using two screwdrivers,pry betweenshims andhousing. Pry assemblyto one side and zero indicator.Pry assemblyto oppositeside and readindicator.
NOTE: Do notzero or read indicator while prying.
5 Amount read on indicator is amount of shimthat should be addedto arrive at zero preloadand zeroend play. Repeatprocedureto ensureaccuracy.Adjust ifnecessa:ry.
6 Shimsare availablein thicknessesfrom 0.080to0.110 inch in 0.002-inchvariations.
41440 7 When sideplay is elminated, a slight bearingdrag will be noticed. Install bearingcaps and tightenbolts to specifiedtorque.
VI
TOOLJ21 784
Fig. 10-40 Adjusting Sideplay
Fig. 10-39 Installing Differential Bearings
10-24 AXLES-PROPELLER SHAFTS
8 Attach dial indicator to axle housingand checkring gear mountingface of differential casefor runoutfig. 10-41.Runoutshouldnot exceed0.002 inch.
9 Remove case from housing. Retain shims usedto adjustsideplay.
Ring Gear Installation1 Placering gearon differentialcase.2 Bolt ring gearto differential case.
NOTE: Two bolts installed in oppositeholes may beusedas guides to pull gear into position.
3 Tighten attaching bolts to 105 foot-poundstorque.
Ring and Pinion Gear Backlash Adjustment
1 Install differential assemblyin housing usingshims previously selectedto remove sideplay.Tightenbearingcap bolts to 87 foot-poundstorque. Attach dialindicatorto housingwith styluscontactingdrive side of atooth on ring gearand at right angleto it fig. 10-42.
2 Move ring gear back and forth andnote movement registeredon dial indicator. Backlashof ring gearshouldbe 0.005 to 0.009 inch, 0.008 inch desired.
3 Adjust backlashasfollows: to increasebacklash,install thinner shim on ring gearside andthicker shimon opposite side. To decreasebacklash, reverseprocedure;however,do notchangetotal thicknessof shims.
Example: Sideplay was removed using 0.090-inchshims on each side totaling 0.180 inch. Backlash ischeckedand found to be 0.011 inch. To correctbacklash,
VI
add 0.004 inch to shim on ring gear side and subtract0.004 inch from shim on oppositeside.
This will result in 0.094-inch shim on ring gear sideand 0.086-inch shim on otherside. Backlashwill be approximately 0.007 inch to 0.008 inch. Total shim thicknessremains0.180 inch.
Differential Bearing Preload Adjustment
Differential bearingsshould be preloaded to compensatefor heat and loads during operation. Correctpreloadis 0.008 inch.
Differential bearingsarepreloadedby increasingeachshim 0.004 inch in thickness.
1 Install differential bearingshims in axle housing bearingbores.
2 Assembledifferential bearingcups on differential bearings.Bearingsshouldcompletelycover differential bearingrollers.
3 Positiondifferential so that bearingsjust startin axle housingbearingboresfig. 10-43.
NOTE: Slightly tipping bearing cups will easestartingcups in to bores. Keep differential assemblysquare inhousingand pushit in asfar as possible.
4 Using plastic mallet, tap outer edgeof bearingcups until seatedin housing.
CAUTION: Do not distort shimsby hammeringthemin to housing.
5 Install bearingcaps,aligning punch markscorrectly. Tighten bolts to 87 foot-poundstorque.
41444
Fig. 10-41 Checking Ring Gear Face of Case for Runout
Fig. 10-42 Checking Backlash
6 Preloading differential hearingsbacklash setting.necessary.
7 Install propeller shaft, aligningmadeat disassembly.
may changeCheck backlash and correct if
index marks
PINION MATESHAFT
DIFFERENTIALCOVERPINION GEAR
DIFFERENTIALSIDE GEARPLUG
AXLES-PROPELLER SHAFTS 10-25
8 Install axle shafts, bearings, seals, and brakesupport plates.
9 Fill rear axle with Trac-Lok Lubricant, orequivalent.
10 Check and adjustaxle shaft end play if necessary. Adjust end play at left side of axle shaftonly.
11 Install hubs, drums, and wheels, and lowervehicle.
OVERHAUL-AXLE MODELS 30-44-60
Disassembly
NOTE: It is not necessaryto removethe axleassemblyto o verh ul the difterential. Refrr to figures 10-44 and10-45 .tiu parts nomenclatureduringoverhaul.
1 Raisevehicleandremoveaxleshafts.2 Removeaxle housingcover andloosenbolts that
retaindifferential bearingcaps.Do not removecaps.
NOTE:: Centerpunchidentification marks on bearingcaps and housingso caps are installed in samepositionat assembly.
3 Spreadaxle housingusing Tool J-25102. Installholddown clampsto keepspreadertool in position fig.10-46. Position dial indicator as shown in figure 10-51and measureamounthousingis spreadby Tool J-25102.Do not spreadhousingmorethan0.020 inch.
BEARING
J42304
VI
Fig. 10-43 Differential Installation
DIFFERENTIALCASE
GASKET
SLINGER
DIFFERENTIALBEARING SHIMS
DIFFERENTIAL
YOKEOIL SEAL
BEARING CUP
FRONT PINION BEARING
FRONT PINION BEARING CUP
HOUSINGAXLE SHAFT
SHIMSBEARING CUP
SEALCUP
THRUST‘WASHERS
WASHERS
BEARI
GASKET
E
Fig. 10-44 Model 60 Rear Axle
10-26 AXLES-PROPELLER SHAFTS
PINION MATESHAFT
I GASKETPLUG THRUST
COVER WASHERS
DIFFERENTIALPINION GEAR
Fig. 10-46 Spreading Axle Housing
4 When housinghas been spreadsufficiently, remove dial indicatorand bearingcaps.
5 Pry differential from housing using pry barsunderheadsof ring gear bolts andcarrier casting.
6 Removespreaderimmediatelyto preventpossibility of housingtaking set.
VI
A 0SLINGER
YOKEDUST CAP
SEALFRONT PINION BEARING
FRONT PINION BEARING CUP‘ BEARING
9 SEAL
[HOUSING / RETAINER
BEARING RETAINER RING
7 Remove bolts that attach ring gear to differential case.
8 Remove pinion mate shaft lockpin usingsmallpunch fig. 10-47.
9 Removepinionmateshaftandthrustblock.10 Removedifferentialpiniongears.
2.
Fig. 10-47 RemovIng Lockpln
J42305
J42307
11 Removepinion nut usingTool J-8614-O1fig. 10-
12 Removeyoke usingTools J-8614-01,-02, -03 fig.10-3.
13 Using rawhide hammer, strike end of piniongearto force pinion out of housing.
DIIFERENTIAL
DIFFERENTIAL PINION DEPTHSHIMS
PINIONPRE LOADSHIMS
CUP
BEARING
THRUSTWASHERS
Fig. 10-45 Model 30 and Model 44 Rear Axle-Typical
HOLDDOWNCLAMPS
SPREADERJ-25102
/ NOTE: Do not losepinion gear thrust washers.
DIAL INDICATOR ANDCLAMP BRACKET
T1fJ42 306
AXLES-PROPELLER SHAFTS 10-27
NOTE: The pinion bearing Jrcloal adjusting shimsmay remain on the pinion shft, or stick to the bearingthat remains in the housing, O, frill out. Theseshimsshould becollectedand retained for assembly.
14 Removeouter pinion bearing,oil slinger,andoilseal, using two-inch by two-inch piece of hardwoodorlength of pipe. Drive cone,slinger, and seal out of housing. Discardseal.
Differential Bearing Removal-Model 30-44 AxleRemove differential bearingsand pinion in:ner bear
ing using Bearing Puller Set J-25100. This puller seteasesremoval of the bearingswithout damagingtheconerollers as pulling pressureis applieddirectly to thebearingfig. 10-48.
NOTE: l’Vhen removlng front axle dfferential innerpnon bearing with oil slinger attached, two pulleradapterSplatesmustbe insertedfrom topinto onesideofJ-5100puller base, then repositioned180degreesapartfIq. 10-48.
Fig. 10-48 Removing Differential Bearing-Models 30-44
Differential Bearing Removal-Model 60 Axle
Removedifferential bearingsusingPressJ-25123,ExtensionJ-25124,Button J-25127,Holding Ring J-25125andAdapterJ-25128fig. 10-49.
Removepinion inner bearingusingPuller SetJ-25123with ReducerRing J-25126and AdapterJ-25128.
Pinion Bearing Cup Removal
1 Usingbrassdrift, drive inner pinion bearingcupand shims from housing. Shims should be kept for assemblyreferenceeven if mutilated.
2 Usingbrassdrift, drive outer pinion bearingcupfrom housing.
EXTENSIONJ-25124
BUTTONJ-25 127
J4231 1
Cleaning and inspection
Clean all parts in solvent. Allow bearingsto air dry.Dry other partswith compressedair.
Inspectdifferential, cups,and bearingrollers for pitting, galling, flat spots,or cracks.
Inspectdifferential casefor elongatedor enlargedpinion mateshaft hole. The machinedthrust washersurfaceareasandcounterboresmust be smoothandfree ofnicks,gouges,cracks,or burrs. Inspectcasefor cracksorother visible damage which would necessitatereplacement.
Inspect pinion mateshaft for excessivewear in contact areaof differential pinions.Shaft shouldbe smoothand roundwith no scoringor metal pickup.
Inspect side gears and pinions. They should havesmooth teeth with a uniform contat pattern withoutexcessivewearor brokensurfaces.The sidegearandandpinion thrust wahers should be smooth and free fromany scoringor metal pickup.
Inspectpinion mateshaft lockpin for damageor loosenessin case.Replacepin or caseas necessary.
Inspectring gear andpinion gearfor worn or chippedteethor damagedattachingbolt threads.If replacementis necessary,replaceboth the ring gear and pinion asmatchedsetonly.
Inspect pinion bearing cones, cups, and rollers forpitting, galling, excessivewear,or othervisible damage.If inspection reveals that either are unfit for furtherservice,replaceboth cup andcne.
Inspectdifferential case for cracks or other visibledamage which might necessitatereplacement.Raisedmetal on shoulderof bearingcup boresincurred in removingpinion. cupsshouldbe flattenedby useof a bluntpunch.
VI
PRESS J-25123
SET RINGJ-25125
TOOL J.25100
VFig. 10-49 Differential Bearing Removal-Model 60
ADAPTERS J42310
10-28 AXLES-PROPELLER SHAFTS
Inspectpinion gearfor damagedbearingjournalsandmountingshim surfacesor excessivelyworn splines.Ifreplacementis necessary,replaceboth the pinion gearand ring gearavailablein matchedsetsonly.
Inspect pinion yoke for cracks, worn splines, pitted,rought or corrodedoil sealcontactingsurface.Repairorreplacepinion yoke as necessary.
Inspect pinion bearingshim pack for broken, damaged, or distorted shims. Replace shims if necessaryduring settingof pinion bearingpreload.
Assembly
Pinion Gear Installation
NOTE: Front axlesusean oil slinger betweenthe bearing cone and the pinion head. If the oil slinger is notinstalledcorrectly, the pinion shimpack dimensionwilbe incorrect.
1 Install outerbearingcup usingDriver J-25101.2 Install inner bearingcup usingInstallerJ-25101
on Model 30 axles, andInstallerJ-25157on Mode] 44 andModel 60 axlesto drive cup into housing.
3 Use SleeveJ-25218to press inner bearingontopinion shaft on axle Models 44 and 60. Use SleeveJ25181 on Model 30 fig. 10-50.
4 Install pinion gear in housingand install 0.065-inch shim, inner bearing, and universal joint yoke tohold pinion in position for pinion depth adjustment.Install pinion nut. Tighten nut only enough to removeend play and allow 10 to 15 inch-poundsof rotatingdrag torque.
SLEEVEJ-25218 ORJ-25181
Pinion Gear Depth
VI
Pinion gear depthrefers to the distancemeasuredininches from the end face of the pinion gear to thecenterlineof the axle shaftsfig. 10-35.This dimensionis controlled by shims which are installedbetweenthepinion gearinner bearingcup and the axle housingfig.10-51.
Ring andpinion gear setsare factory testedto detectmachiningvariances.The testis startedat a standardsettingwhich is then variedto obtain the mostdesrab]etooth contactpattern and quiet operation.When thissetting is determined,the end of each pinion gear isetchedwith a plus+, minus-, or zero number. Thisnumberindicatesthe amount,in thousandthsof an inch,that thegearset variedfrom the standardsettingandisthe pinion depthvariance.
Fig. 10-51 Differential Shim Locations
J42 312
The standardsettingfor axle Models30, 44, and60 areas follows:
* Model 30: 2.250* Model 44: 2.625* Model 60: 3.125
If the pinion is marked +2, the gearset varied fromthe standardsettingby 0.002 inch andwill require0.002inch less shims than a gear set marked0 zero. Whenthe piniongearis markedplus+, the distancefrom thepinionendfaceto the axle shaftcenterlinemustbemore
J42313 thanthe standardsetting.If thepinion is marked-3, thegear set will require 0.003 inch more shimsthana gearset marked0 zero.
BEARING PRE LOADSHIM PACK
DEPTH
DIFFERENTIAL BEARINGSHIMPACKS
Fig. 10-50 Installing Pinion Bearing
AXLES-PROPELLER SHAFTS 10-29
When the pinion gear is marked minus -, the distance from the pinion end faceto the axle shaftcenterline must be less than the standardsetting. Refer tofigure 10-35 for an illustration of standard settingdimension.
Pinion Gear Depth AdjustmentObservethe pinion depth variancemarkedon the pi
non gear.If the numberis precededby a plus + sign,add that amountin thousandsto the standardsettingfor the axle model being overhauled.[f the numberisprecededby a minus - sign, subtractthat amount inthousandsfrom the standardsetting.The result of thisaddition or subtraction is the desiredpinion depth.Record this figurefor further reference.
NOTE: If the gear is marked0 zcro, use the standardsetting.
1 AssembleArbor Tool J-5223-4and DiscsJ-5223-26 Model 30 axle or Discs J-5223-25Model 44 and 60axles and install in differential bearing cup bores inaxle housing fig. 10-52. Be sure discs are seatedinbearingcup bores.
6 Extendclampbolt until it pressesagainstgaugeblock with enough force to prevent gaugeblock frommoving.
7 Loosen thumbscrewin gauge block to releaseplunger. When plunger contacts arbor tool, tightenthumbscrewin gaugeblock to lock plunger in position.Do not disturb plungerposition.
8 Remove clamp and bolt assembly from axlehousing.
9 Removegaugeblock and measuredistancefromend of anvil to end of plunger using a 2- to 3-inch micometer fig. 10-53. This dimension representsthemeasuredpinion depth. Recordthis dimensionfor assemblyreference.
10 Removehearingcapsand removearbor tool anddiscs from axle housing.
11 Removepinion gear,rearbearingcup,anddepthshim from axle housing.
12 Measurethickness of depth shim removed instep 10. Add this dimensionto measuredpiniondepthobtainedin step9. From this total, subtractthe desiredpinion depth. The result representsthe correct shimthicknessrequired.
NOTE: Desired pinion depth is the standard settingplus or minus thepinion depthvariance.
2 Install differential bearing capsin axle housingand over discs.Tighten bearingcap bolts securely,butdo not tighten to specified torque.
3 Install PlungerJ-5223-27in GaugeBlock J-5223-20. Compressplunger andtighten thumbscrewin gaugeblock.
4 Position Gauge Block J-5223-20on end face ofpinion gearwith anvil endof gaugeblock seatedon gearandplungerunderneathArbor Tool J-5223-4fig. 10-52.
5 Install bolt J-5223-29 in Clamp J-5223-24andmountassemblyon axle housingfig. 10-53. Usehousing cover bolt to attachclamp to housing.
The following examplesillustrate the procedurefor determiningcorrectshim thickness.
ExampleI-Pinion DepthVarianceis Plus+ Model 44Axle
Step1-Determinedesiredpinion depth.
Add piniondepth variancemarkedon piniongear tostandardsetting.Resultis desiredpinion depth.
2.625+0.004
2.629
VI
Fig. 10-53 Measuring Gauge Block
Fig. 10-52 Installing Pinion Depth Gauge Tools
10-30 AXLES-PROPELLER SHAFTS
Add mesuredpiniondepthto measureshim thickness.Resultis total measuredpinion depth.
2.601+0.107
2.708
Subtract desiredpinion depth from total. measuredpinion depth.Result is correctshim thickness.
2.708-2.6290.079
ExampleTI-Pinion Depth Variance is Minus - Model60 Axle
Subtract pinion depth variancemarked on piniongear from standardsetting. Result is desiredpiniondepth.
Add measuredpinion depthto measuredshim thickness.Resultequalstotal measuredpinion depth.
Subtract desiredpinion depth from total measuredpinion depth.Result is correctshim thickness.
-3.1230.097
13 Install correct thickness shim in bearing cupbore of axle housingand install rear bearingcup andpinion gear.
Clearancebetweenthe differential side gearsandcaseshould he 0.000 inch to 0.006 inch. With the differentialpositionedon endfig. 10-54,tap the differential lightlyon a flat surfacesodifferential gearssettle in position.Measurethe clearancebetweeneach side gear and thecasewith feelergauges.If clearanceexceeds0.006 inch,addshims betweenthe gearsand case.
NOTE: If shimsare required, at leastoneshim.shouldbeplaced on. eachside and the shimpackskeptas evenas possbie. After adding shims, repeat the clearancecheck.
Fig.10-54 Checking Side Gear Clearance
Differential Bearing Preload and Ring Gear Backlash Adjustment
Differential bearing preload is controlled by shimsbetweenthe differential caseand differential bearing.
1 Install differential case and bearings in axle
3.125 housingwithout shimsandwith bearingcupssnug.
-0.002 2 Hold ring gearin contactwith pinion, usescrew
3123 driver to move differential bearingcups toward center,and insert feelergaugeon eachside betweendifferential bearingcup andaxle housing.Thereshould be only0.001 inch to 0.002 inch backlashremainingwith feelergaugeinserted.
3 After shim pack requirementfor each bearing3.120 hasbeenestablished,removedifferentialassembly.Make
+0.100 up shim packsandkeepseparated.3.220 4 Add additional 0.015-inch thicknessof shimsto
packon tooth side of ring gear.5 Placedifferential bearingshim packson differ
ential case under each bearing. Install bearings withDriver J-25136for Model 44 rearaxleandDriver J-25519
3.220 for Model 60 rearaxle fig. 10-55.
NOTE: Whenoverhaulingfront axledifferential, checkaxle inner oil seals.Shouldnew seals berequired,installu.sing Tool J-25111for Model44 axle fig. 10-56.
6 Attach Carrier SpreaderJ-25102,install dial indicator,andspreadcarrier maximum of 0.020 inch.
7 Removedial indicator.8 Lubricate bearings and install differential in
housing.9 Tap unit into placeusingplastic mallet. Be sure
ring gear teethmeshwith pinion teeth.10 Apply sealing compound to bearing cap bolt
threads.Tighten bolts to 40 foot-poundstorqueMode]30 or 80 foot-poundstorqueModel 44 and60.
11 Install dial indicatorand check ring gearbacklash fig. 10-57.Check backlashat two points.Backlashmust be between0.005 inch to 0.010 inch. If backlashisincorrect, install shims between differential bearingshim packsuntil correctbacklashis obtained.
Step2-Determinetotal measuredpinion depth.
VI
Step3-Determinecorrectshim thickness.
Step1-Obtain desiredpinion depth.
J42317
Step2-Determinetotal measuredpiniondepth.
Step3-Determinecorrectshim thickness.
Differential Side Gear Adjus’nent
AXLES-PROPELLER SHAFTS 10-31
‘I
Fig. 10-55 Installing Differential Bearings
J42318
NOTE: Changing position of a i.00,5-in,ch shim fromoneside to the otherwill changethe a mountof backlashapproximately 0.003 inch.
12 Check ring gear runout. A readingin excessof0.006 inch indicates sprung differential case,dirt betweencaseandgear,or loose ring gearbolts.
13 Removeuniversaljoint yoke and instail oil sealusing Driver J-25104on all axles exceptModel 60 rearaxle. Use Driver J-25110on Model 60 rearaxle.
14 Install yoke on pionion andinstall pinion washerand nut. Tighten nut to 210 foot-poundtorqueModels30 and44 or 260 foot-poundstorqueModel 60.
15 Install axle shaftsandaxle housingcover.
Fig. 10-56 installIng inner Oil Seals
Fig. 10-57 Checking Ring Gear Backlash
TRAC-LOK DIFFERENTIAL
AssemblyDlsassembiyDraIning LubricantLubrication
OperationOperational TestTrouble SymptomsTrac-Lok Replacement .
OPERATIONA conventionaldifferential transmits all of the ring
gear torque through the differential gears to th.e axle
shafts. Torque is at all times equalon the axle shafts,and if one wheel slips, the other wheel can only put outas much torqueas the slippingwheel.
VI
1.
J42319
J42 320
AI
Page10-3510-3210-3210-32
Page10-3 110-3210-3210-37
10-32 AXlES-PROPELLER SHAFTS
The Trac-Lok differential differs in that part of thetorquefrom the ring gearis transmittedthrough clutchpacksbetweenthe side gearsand differential case.Themultiple disc clutcheswith radial grooveson the platesand concentricgrooveson the discs are engagedby apreloadfrom Belleville springs,plus separatingforcesfrom the side gearsas torqueis appliedthroughthe ringgear.
The Trac-Lok constructionpermitsdifferential actionwhen required for turning cornersand transmitsequaltorque to both wheels when driving straight ahead.However, when one wheel encountersice or leavestheground and spins, the clutch packsautomaticallyprovide moretorqueto the wheelwhich is not spinning.TheTrac-Lokdifferential resistswheelspin on bumpyroadsand providesmore pulling power when one wheel triesto slip. Pulling power will be automatically provideduntil both wheelsstartto slip. If, with unequal.traction,both wheels slip, Trac-Lok operationis normal. In extremecasesof differencesin traction, the wheelwith theleast traction may spin after the Trac-Lok has transferred as much torque as possibleto the nonslippingwheel.
LUBRICATIONThe Trac-Lokdifferential requiresa speciallubricant.
Ordinary multipurposegearlubricants MUST NOT beused.Use JeepTrac-Lok Lubricant or equivalentonly.
Trac-Lok differentials may be cleaned only by disassembling the unit and wiping it clean with shoptowels.
NOTE: The Trac-Lok differential is serviced at thesametim.e intervals as the standarddifferential.
TROUBLE SYMPTOMSIf noises or roughnesssuch as chatter occur when
turning corners,the probablecauseis incorrect or contaminatedlubricant.
Before any differential is removedand disassembledfor chattercomplaints,checkto seeif proper lubricantisused.
A complete lubricant drain and refill with specifieddifferential lubricant will usuallycorrectchatter.
DRAINING LUBRICANT1 Warm lubricantby driving vehiclefor 5 minutes
of operationin gear at 30 mph with wheelsoff groundon hoist.
WARNING: Never shift the transmission into gearwith the en.ginerunning when.only onewheelofa TracLok equippedvehicleis raised. The vehiclecould propelitselfoff thejack and causedamageorpersonalinjury.
2 Drain lubricantwhile warm. Removedrain plugor cover to drain completely.If coveris removed,it maybe necessaryto replacegasketat this time.
VI
3 Refill axlewith specifiedlubricant.4 Operate vehicle for approximately ten miles,
making at leastten figure-eightturns to flush old lubricantoutof clutch packs.
5 Repeatsteps2 through4, above,makingsureto replacecovergasketif required.
NOTE: If slight chatter occurs after draining andflushing Tra,c-Lock,drive vehicle an. additional 10 to 20milesor until chatterstops.If chatterstill persistsafterthe lubricant change, disassemblyand repair will benecessary.
OPERATIONAL TESTA properly functioning Trac-Lok unit can be deter
mined by the following operationaltest.Placeonewheel on good dry pavement,andthe other
on ice, mud, grease,etc.Gradually increaseengine rpm to obtain maximum
traction prior to breakaway.The ability to move thevehicle effectively will demonstrate properperformance.
If extremelyslick surfacessuch as ice or greaseareused,somequestionmay existas to properperformance.In theseextremecases,a properlyperformingTrac-Lokwill provide greaterpulling power by lightly applyingthe parkingbrake.
DISASSEMBLY1 Remove Trac-Lok differential from axle hous
ing. Removalproceduresaresameasoutlinedfor standard differential. Refer to Figure 10-58 for partsnomenclature.
2 Install one axle shaft in vise with splineend upand tighten vise. Do not allow more than 2-3/4 inch ofshaft to extend abovetop of vise fig. 10-59. This willprevent shaft from fully entering side gear, causinginterferencewith stepplate tool usedto removedifferential gears.
3 Mount differential case on axle shaft with ringgearbolt headsfacingup fig. 10-60.
4 Removeanddiscardring gearbolts.5 Place shop towels on vise under ring gear to
protectgear when it is removedfrom casefig. 10-60.6 Remove ring gear from case using rawhide
hammer.7 Remove differential case from axle shaft and
removering gear.8 Mount differential caseon axle shaft.9 Removesnaprings from pinion mateshaftfig.
10-61. Use two screwdriversto disengagesnap rings.Placeshoptowel on oppositeopeningof caseto preventsnaprings from flying out of case.
NOTE: On Model 60 Trac-Lok, pinion mate shaft isretained in case by roll pin. Use 3/16-inch diameterpunchto removepin.
AXLES-PROPELLER SHAFTS 10-33
DIFFERENTIALTHRUST SNAP SIDE 2
RING 2WASHER 2
///PINION MATESHAFT
Fig. 10-58 Trac-Lok Differential
Fig. 10-59 Axle Shaft Positioned In Vise
J42323
10 Remove pinion mate shaft using hammer andbrassdrift.
Fig. 10-60 DifferentIal Mounted on Axle Shaft
VI
DIFFERENTIALPINNION GEAR 2
/,DIFFERENTIALBEARING
BEARINGCUP
RING GEAR
CASE60654
J42324
NOTE: GearRotating Tool J-23781is required to per.t’orm the fbiiowing steps. The tool consists of threeparts: gear rotating tool, forcing screw,and stepplate.
11 Install step plate in lower differential side gearfig. 10-62.
10-34 AXLES-PROPELLER SHAFTS
J42326
J42 327
12 Positionpawl end of gear rotating tool on stepplatefig. 10-63.
13 Insert forcing screw through top of case andthreadinto gear rotating tool.
NOTE: Befbre using forcing screw, apply daub ofgreaseto centeringhole in. stepplate and oil threadsof.fbrcing screw.
14 Centerforcing screw in step plate and tightenscrewto move differential side gearsawayfrom differential pinion gears.
15 Removedifferential pinion gear thrustwashersusingfeelergaugeor shim stock of 0.030-inchthickness.Insert shim stock or gaugebetweenweasherand caseandwithdraw shim stockandthrustwasherfig. 10-64.
16 Tighten forcing screw until a slight movementof differential piniongearsis observed.
17 Insert pawl end of gear rotating tool betweenteeth of onedifferential side gear.Pull handleof too] torotateside gearsand pinion gears.Removepinion gearsas they appearin caseopeningfig. 10-65.
J42330-
NOTE: It may be necessaryto adjust tension appliedon. Behievihiesprings by tighteningscrewbeforegearscanbe rotatedin case.
18 Retain upperside gear and clutch pack in caseby holding handon bottomof rotatingtool while removing forcing screw,Removerotatingtool, uppersidegear,andclutch pack.
19 Removedifferential casefrom axle shaft.Invertcasewith flange or ring gearside up and removestepplate tool, lower side gear,and clutch pack from case.Removeretainerclips from both clutch packsto allowseparationof platesanddiscs fig. 10-66.
VI
Fig. 10-61 RemovIng Snap Rings from Pinion Mate Shaft
Fig. 10-64 RemovIng Pinion Thrust Washer
J42329
Fig. 10-62 installing Step Plate
Fig. 10-65 Removing Pinion Gears
Fig. 10-63 Installing Gear Rotating Tool
VI AXLES-PROPELLER SHAFTS 10-35
J42331
Clutch Plates and Disc
If any one memberof either clutch pack showsevidenceof excessivewear or scoring,t.he completeclutchpack musthe replacedon both sides.
Differential Side and Pinion GearsThe gear teethshould he checkedfor extremewearor
possible cracks. The external teeth of the side gearwhich holds the clutch pack also should be checkedforwear or cracks. If replacementof one gear is requireddue to wear, both side gears,pinion gears,and thrustwashersmustbe replaced.
Pinion Mate ShaftIf excessivewear is evidenton any oneof the retainer
clips, it is suggestedthat all clips be replaced.
Differential Case
If scoring, wear, or metal pickup is evident on themachined surfaces, then replacementof the case isnecessary.
Examples of radial groove clutch plate A and theconcentricgroovedisc B areshown in figure 10-67.
J42332
ASSEMBLY1 Lubricate differential gear teeth, thrust faces
andsplines.Lubricateclutch discsand plates.UseTracLok lubricant or equivalentonly.
2 Assembleclutch packs.Install platesand discsin sameposition as whenremovedregardlessof whetherthey are replacementor original parts.
3 Install clutch retainer clips on ears of clutchplates.Be sureclutch packs are completelyassembledandseatedon ears of plates.
4 Install clutch packs on differential side gearsand install assemblyin case.
NOTE: .Besnrc clutch pack stays assenibled on sidegear ,splines and that retainer clips are completelyseated in case]ochet.s. To prei.’ent pack.from.faliing outof case, it will be necessaryto hold them in place byhand nh lie moantiny caseon axlesh.aft fig. 10-68.
5 Mountcaseassemblyon axle shaftfig. 10-68.
Fig. 10-66 Removing Side Gear and Clutch Pack
inspection
Fig. 10-68 Mounting Differential Case on Axle Shaft
Fig. 10-67 Plate and Disc Identification Fig. 10-69 Installing Clutch Pack and Side Gear
10-36 AXLES-PROPELLER SHAFTS
CAUTION: When installing differential caseon axle,sh,ft, be sure that splinesof side gearsare aligned withthoseof axle shaft. Be sure clutchpackis still properlya.ssembled in caseafter installing caseon axleshaft.
6 Install step plate tool in side gear.Apply smalldaubof greasein centeringhole of step plate.
7 Install remainingclutch pack and side gear.Besure clutch pack stays assembledon side gear splinesand that retainerclips arecompletelyseatedin pocketsof casefig. 10-69.
8 Positiongearrotatingtool in upperside gear.9 Keep side gear and rotating tool in position by
holding with hand.Insert forcing screw through top ofcaseandthreadinto rotating tool fig. 10-70.
10 Install both differential pinion gearsin case.Besureboresof gearsare aligned.Hold gearsin placebyhandfig. 10-71.
Fig. 10-70 Threading Forcing Screw into Rotating Tool
11 Tighten forcing screw to compress Beilevillespringsand provide clearancebetweenteeth of piniongearsandside gears.
12 While holding pinion gearsin place,insert paw]of rotating tool between teeth of side gear. Pull onhandle to rotate gear and allow pinion gears to beinstalled.
VI
NOTE: It may benecessaryto adjustforcingscrew byvery slightly looseningor tighteninguntil required loadis applied to Believille springs to allow side and piniongears to rotate.
13 Pull on tool until handlehits gear.Removepaw]from between gear teeth and reposition handle andpawl. Repeatsameoperationuntil holes of both piniongearsarealignedwith thoseof case.
14 Lubricateboth sidesof piniongearthrustwashers with Trac-Loklubricant or equivalent.
15 Apply torque to forcing screwto allow installation of thrustwashers.
16 Install washersin case.Use smallscrewdrivertopushwashersinto place fig. 10-72.
CAUTION: Be sure holes of washersand gears areaignedwith. thoseofcase.
17 Removeforcing screw, rotating tool, and stepplate.
18 Lubricate pinion mateshaft and install in caseusing hammer. Be suresnap ring groovesof shaft areexposedto allow assemblyof snaprings fig. 10-73.
19 Install snaprings.
Fig. 10-72 Installing Pinion Gear Thrust Washers
J42336
J42338
Fig. 10-71 Starting Pinion Gears into Case
J42337
J42 339
Fig. 10-73 Installing Pinion Mate Shaft
AXlES-PROPEllER SHAFTS 10-31VI
NOTE: On Model 60 Trac-Lok, align hole in shaftwithhole in case.Drive shaft into position and install retaining roil pin. If caseis positionedin vise with machinedside of ring gear flange facing upward, use 5/16-inchdiameterpunchto install roll pin until punch bottomsincase bore. If case is positioned in vise with machinedside of ring gearflangefacing downward,wrap pieceoftape around 3/16-inchdiameterpunchapproximately1-3/4 inch away from endof punch and install roll pin incaseuntil edgeof tape is flush with roll pin bore.
20 Removecasefrom axle shaft. Install ring gearon case.
NOTE: Use new ring gear bolts only. Do not useoriginal bolts.
21 Align ring gear bolt holes with those of case.Install ring gearbolts finger-tight.
22 Mount differential case on axle shaft, andtighten bolts evenly to specified torque. Refer to TorqueSpecifications.
23 Install Trac-Lok differential assembly in axlehousing.Follow serviceprocedurespreviously out]medfor conventionalaxlesto completedifferential and axleassemblyservicing.
TRAC-LOK REPLACEMENTIf inspectionrevealsthat replacementof the Trac-Lok
as a unit is required, the following steps should befollowed.
1 Removedifferential bearingsand shims. Markor tag each bearing and shim pack to indicate fromwhich side of the casethey wereremoved.
2 Removeringgearfrom case.3 Install ring gear on case.Be.suregearflange on
differential caseis free of nicks or burrs.4 Inspect shims and bearings which were re
moved. If shims and bearingsshow excessivewear ordamage,they should be replaced. Be sure shims andbearingsare usedon samesidesof replacementcaseason old case.
5 Install shimsanddifferential bearings.Use stepplateon bottombearingto protectbearingfrom damageduring installationof upperbearing.Seatbearings,using bearingdriver tool.
6 Lubricate differential bearingswith specifiedlubricant andinstall casein axle housing.
7 Follow service procedurespreviously outlinedfor conventionalaxlesto completedifferential andaxleassemblyservicing.
PROPELLER SHAFTS AND UNIVERSAL JOINTS
PageCardan Cross-Type Universal Joint 10-37
GENERALTorque transfer from the transfer caseto the front
and rear axles is accomplishedby means of tubularpropellershafts.Eachshaft is equippedwith a universaljoint at eachend.
Becauseof the variouscombinationsof drive line components,severaltypesof propellershaftsare required.
Always checkthe replacementpropellershaft for correctpart numberbeforeinstallation.
Both the propeller shafts and the universal jointsshould be checkedregularly for foreign matter on theshafts,dentedor bentshafts,and looseattachingbolts.Refer to Section B-Maintenancefor properILubricationrequirementsandspecifications.
Universal Joint ServiceEachshaft is equippedwith asplinedslip joint at one
end to allow for variations in length causedby vehiclespring action.The yokesat the front andrearof te shaftmust be aligned in the samehorizontal plane. This isnecessaryto avoid vibration.
PageGeneral 10-37
CARDAN CROSS-TYPE UNIVERSAL JOINT
Disassembly
NOTE: Repairof single and double Cardanjoints aresimilar except for the center ball and socketin thedouble Cardanjoint fig. 10-74. The rollers and bushings are replaceableoncethe joint is disassembled.
1 Positiontube or propellershaft, nearcross-typeuniversaljoint, in vise andclamptightly.
2 Remove two cup retainer rings, which fastenbearing cups to tube yoke. If necessary,tap ends ofbearingcups with brasshammerto releasepressureonretainerrings beforeremoval.
3 Mount joint in vise so that earson one yoke aresupportedon vise jaws.
4 Using brasshammer,strike earof yoke behindbearingto drivebearingout. Removeoppositebearinginsamemanner.
5 Removecrossfrom yoke.
10-38 AXLES-PROPELLER SHAFTS
BALL FITTINGYOKE
Fig. 10-74 Double Cardan Joint
6 Disengageand remove tie link from bearingblock retainers. Remove retainers and roller bearingcups from cross.Removebearingsealsand seal retainersfrom cross.
7 Clean tube yoke of propeller shaftwith suitablecleaningsolventanddry thoroughly.
8 Inspectyoke for wearand damage.If bentout ofalignment with propellershaft tube, or if bearingboresareworn or damaged,replacepropellershaft.
Model 30 Front Axle
Assembly
1 If crossof universaljoint hasnot beenreplaced,install four new sealretainersand bearingseals,oneoneacharm of cross.
2 Install two roller bearingcup assemblies,on oppositearmsof cross.
3 Install bearing block retaineron each bearingcup, and connectretainerswith tie link to fastenbearings to cross.
4 Thread remainingarms of cross,which do notcarry bearings,into tubeyoke.
J42340 . . .
5 Position yoke in vise, so that inner surfaceissupportedby vise jaws.
6 Usingbrasshammer,tap roller bearingcup assembly into bearingof yoke, so that bearingfits overendsof cross.Drive bearingcup downwarduntil retaining ring groove is fully exposed below yoke innersurface.
7 Attach bearingto yoke using a retainerring; besureretainerring is properlyseated.
8 Reverse yoke on vise and repeat steps 5through7, above,to install oppositebearingassembly.
SPECIFICATIONSAdjustments
Model 60 Axle Continued
Differential Bearing PreloadDifferential Side Gear-to-Case
ClearanceDrive Gear-to-Pinion BacklashDrive Pinion Bearing Break
Away PreloadOriginal BearingsNew Bearings
Model 44 AxleFull-Floating and Semi-Floating Types
Differential Bearing PreloadDifferential Side Gear-to-Case
ClearanceDrive Gear-to-Pinion BacklashDrive Pinion Bearing Break
Away PreloadOriginal BearingsNew Bearings
Model 60 Axle
Differential Bearing PreloadDifferential Side Gear-to-Case
Clearance
.015 in
.000-.006 in
.005-.009 in
15-25 in-lbs20-40 in-lbs
.015 in
.000-.006 in
.005-.010 in
Drive Gear-to-Pinion BacklashDrive Pinion Bearing Break-Away
Original BearingsNew Bearings
Axle Shaft End Play Shims-Left Side Only
Bearing Preload CollapsibleSleeve
Differential Bearing PreloadShims
Differantial Case FlangeRunout
10-20 in-lbs Inspection only-no adjustment20-40 in-lbs Differential Gear-to-Case
Preload Adjusted UsingOversize Thrust Washers .
Ring Gear-to-Drive Pinion
.015 in
.000-.006 in
Gear Backlash Shims . .
Pinion Gear StandardSetting Shims
AMC - Jeep AxleSemi-Floating Tapered Shaft
.005-.009 in
10-20 in-lbs20-40 in-lbs
.004-.008 in.006 in desired
17-25 in-lbs
.008 in
.002 in max
0-180 in-lbs
.005-.009 in.008 in desired
2.547 in
U-JOINT ASSY.PROP.-TO -TRANSFERCASE YOKE
INSERT
SPRING
VI
U-JOINT ASSY,COUPLING YOKE-TO-PROP.
VI
Torque Specifications
AXLES-PROPELLER SHAFTS 10-39
Axle Housing CoverDifferential Bearing BoltsDrive Gear-to-Case BoltsLower Ball Joint NutPinion Yoke NutUniversal Joint U-BoltsUpper Ball Joint NutUpper Ball Stud SeatWheel-to-Hub Nuts
Model 44 Axle
Axle Housing CoverBacking Plate Mounting Bolts/Nuts
Front BrakesRear Brakes
Differential Bearing BoltsDisc Brake Shield BoltDisc Brake Shield NutsDrive Gear-to-Case BoltsLower Ball Joint NutPinion Yoke NutUpper Ball Joint NutUpper Ball Stud SeatUniversal Joint Flange BoltsUniversal Joint U-BoltsWheel-to-Hub Nuts
Axle Housing Cover BoltsBacking Plate Mounting
Bolts/NutsDifferential Bearing BoltsDrive Gear-to-Case BoltsPinion Yoke NutUniversal Joint Flange BoltsUniversal Joint U-Bolts
80 - Wheel-to-Hub Nuts
210 200-220
‘50 -35 25-4515 13-1880 65-90
Axle Cover ScrewBrake Tubing-to-Rear Wheel
Brake Cylinder
Differential BearingCapscrew
Ring Gear-to-CaseScrew
Rear Brake Support PlateScrew Nut
Rear Wheel Hub-to-ShaftNut
Universal Joint U-BoltClamp
ServiceIn-Use
RecheckTorques
20 15-25
Pinion Angie Chairt
Front Rear
OK Range Set-To OK Range Set-To
Nac;oneer --
CherokeeQuacra-Trac
80 7090‘
50 4060
CheokeeDana 20 8° 7.90
50 4°-6°
eJ25 8° 70 90 3°30 2°30’- 4°30’
TruckModel 45
80 7°-9° 5° 4°-6°
Service Set-To Torques should be used when assemblingcomponents.Service In-Use Recheck Torques should be used for checkinga pre-torqued item.
Model 30 Front Axle
Model 60 Axle
ServiceSet-ToTorques
ServiceIn-Use
RecheckTorques
ServiceSet-ToTorques
20 15-2545 35-5055 45-65
21015
200-22013-18
50801052603515120
45-5570-90
100-110250-270
25-4513-18
110-125
100 -50 -80 65-90
Full-Floating and Semi-Floating Types
AMC-Jeep AxleSemi-Floating Tapered Shaft
20 15-25
28 25-3030 25-3580 70-908 5-10
35 30-4055 45-6580
170 in-lbs 150-190 in-lbs
97 in-lbs 90-105 in-lbs
87 80-95
105 95-115
32 25-40
250 Mm 250 Mm
13 10-18
100 - All torque values given in foot-pounds with dry fits unlessotherwise specified.Refer to the Standard Torque Specifications and CapscrewMarkings Chart in Section A of this manual for any torquespecifications not listed above. 60657A
70556
10-40 AXLESPR0PELLEH SHAFTS
.1-25173 FLANGEINSTALLER
J-25119 DRIVER
J-25101 DRIVER
a.1-25180 PULLER
Special Tools
vu
.1-25105 AND .1-25106 WRENCH .1-25103 WRENCH
.1-25100 PULLER SET.1-25124 EXTENSION
J-25136 DRIVER.1-25135 DRIVER
.1-25127
.1-25218 SLEEVE BUTTON
.1-25181 SLEEVE
4’.1-25111 INSTALLER
.1-25104 DRIVER
.1-25133 PULLER
J-25157 INSTALLER.1-25122 HANDLE
J42341
Special Tools
AXLES-PROPELLER SHAFTS 10-41
.1-25211-1 PLATE .1-25211-2 CUP
J-25211-4 ADAPTER
J-25158 WRENCHNUT
J-25170 DRIVER AND ADAPTER
ww
J-2619-01 SLIDE HAMMER
.1-25128 ADAPTER
J-25123 PRESS SET
vu
J-25211-3 BUTTON
J-25215 PULLER
.1-25102 SPREADER
J-25126 REDUCER RING.1-25125 HOLDING RING
J42 342
10-42 AXLES-PROPELLER SHAFTS
J-21786REAR PINIONBEARING REMOVER
- .- .J-8092 J-8592 -DRIVER HANDLE
aJ-9233PINION OIL SEAL REMOVER
J86O8REAR PINION BEARINGCUP INSTALL ER
J-21 784AXLE DIFFERENTIALBEARING INSTALLER
fl,11fl*1IIE1uniiut.:J-22697 REAR PINIONBEARING INSTALLER
J-8001DIAL INDICATOR SET
J-861 4.01YOKE HOLDING TOOL
J.8611-O1FRONTPINIONCUP BEARINGINSTALLER.
J-2266 REAR PINIONOIL SEAL INSTALLER
J-8614-2J8614-3YOKE REMOVERTOOLS
4S--- J-23781-7 STEP PLATE J-2498AXLE SHAFT REMOVERTAPERED AXLE SHAFT
L.J.22575PINION NUT SOCKET
J-2092 - 7-9/16 OR 8-7/8 INCH AXLEEND PLAY CHECKING TOOL
J-2497-01DIFFERENTIAL BEARING PULLER
0J-21 787FRONT PINIONBEARING CUPREMOVER
Special Tools
VI
II
1..J-5223-03 SET
J-21 788AXLE SHAFT OILSEAL INSTALLER
J-5223-03PINION SETTING GAUGE
I
F
J-8646-2 FORCING SCREWJ-23781 .3GEAR ROTATING TOOL
A41472